Removal and Replacement
Camshaft Drive Belt, Removing, Installing and Tensioning
Special Tools and Equipment
- 10-222 A Engine Support Bridge 10-222A/8 Engine Support Feet
- T 10020 Toothed Belt Tensioner
- VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb) (or equivalent)
- VAG 1332 Torque wrench 40 to 200 Nm (30 to 148 ft lb) (or equivalent)
10-222 A/21 guide from 10-222 A support tool, modifying
- Use 10-222 A support tool to support engine/transmission.
- Drill a new hole to fasten 10-222 A/8 adapter to 10-222 A/21 guide.
- Drill one hole 12.5 mm diameter (arrow) in 10-222 A/21 guide.
Removing
- Remove engine cover.
- Remove right-hand insulation tray.
- Remove ribbed belt.
- Remove ribbed belt tensioning element.
Engine Installed
- Turn crankshaft to cyl. 1 TDC -arrow-.
- Vehicles with manual transmission
- Turn crankshaft to cyl. 1 TDC -arrow-.
- Vehicles with automatic transmission
Engine Removed
- Turn crankshaft to cyl 1 TDC -arrows-.
- Remove coolant expansion tank and place to one side
- Pull off vacuum pipes at EVAP canister and at throttle valve housing.
- Remove camshaft drive belt guard - upper section
- Install 10-222A support with legs 10-222 A/8 as shown.
- Remove bolts -arrows- and engine mount -1- as follows;
- Unscrew bolts -arrows-
- Loosen bolt -arrow A-
- Remove vibration damper/belt pulley.
- Remove camshaft drive belt guard center and lower sections.
- Remove bolts for engine bracket from cylinder block -arrows-.
Note:
- To loosen front screw from bracket, raise engine slightly using the support bracket.
- Mark direction of rotation on belt.
- Release belt tension and take off belt.
- Turn crankshaft back slightly.
Installing
Note:
- When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns..
A - Camshaft drive belt completely removed
Conditions
- Pistons must NOT be positioned at TDC.
Work sequence
- Bring mark on camshaft into line with the mark on cylinder head cover.
- Place camshaft drive belt on crankshaft sprocket and coolant pump (observe engine direction of rotation).
- Install bracket to engine block: Tightening torque 45 Nm (33 ft lb)
Note:
- Insert screws before installing engine support.
- Install camshaft drive belt guard center and lower sections.
- Install vibration damper/pulley. Tightening torque: 40 Nm (30 ft lb)
- Turn crankshaft to cyl. 1 TDC -arrows-
- Install engine mounts (replace bolts)
- Align engine and transmission mounts.
- Install coolant expansion tank.
- Install vacuum pipes at EVAP canister and at throttle valve housing.
- Place camshaft drive belt on tensioning roller and camshaft sprocket and tension.
- Remove 10-222 A support.
B - Camshaft Drive Belt, Removed from Camshaft Sprocket Only
Conditions
- Pistons must NOT be positioned at TDC.
Work sequence
- Align mark on camshaft with line on cylinder head cover.
- Turn crankshaft to TDC cyl. 1.
- Place camshaft drive belt on camshaft sprocket and tension.
Camshaft Drive Belt, Tensioning
Requirements
Engine must be more than warm to the touch.
Camshaft sprocket at cyl. 1 TDC.
Before tensioning camshaft drive belt turn tensioning roller on eccentric with a pin wrench T10020 five times in both directions fully onto the stops.
Work Sequence
- Tension camshaft drive belt. Do this by turning eccentric to left (direction of arrow) with two hole pin wrench T 10020 onto stop.
- Tension is correct when notch -1- and indicator -2- align. (Check using mirror).
- Tighten securing nut: 20 Nm (15 ft lb)
- Turn crankshaft two turns in engine direction of rotation until the engine is again at TDC Cyl. 1. When doing this it is important that the last 45 ° (1/8 turn) turn is performed without stopping.
- Check camshaft drive belt again.
- Specification:
- Notch -1- and indicator -2- align.
- Install camshaft drive belt guard, upper section.
- Install ribbed belt tensioner and torque to 25 Nm (18 ft lb)
- Install ribbed belt.
- Install sound dampening pan and engine cover.
Semi-automatic toothed belt tensioning roller, checking
Special Tools and Equipment
- T100200 Two hole wrench
- Mirror
Installation position
Angled retainer -arrow- must be located in cut-out on cylinder head.
Conditions
- Engine must not be more than warm to the touch.
Test sequence
- Place camshaft sprocket on cyl. 1 TDC
- Press hard with thumb on camshaft drive belt. Indicator -2- must move (use mirror).
- Turn crankshaft two rotations in direction of engine direction until engine is again at TDC Cyl 1. When doing this it is important that the last 45 ° (1/8 turn) turn is performed without stopping. Check camshaft drive belt again.
- Tensioning roller must return ti its original position (notch -1- and indicator -2- align again).
Note:
- Check using a mirror.