Timing Belt: Service and Repair
Toothed belt, removing and installing
Special tools and equipment
^ 3359 Pin
^ T10004 Two-hole pin wrench (or T10020)
^ T10115 Pin
^ T10050 Crankshaft stop
^ VAG1331 Torque wrench (5 to 50 Nm)
^ VAG1332 Torque wrench (40 to 200 Nm)
Special tools and equipment
^ 10-222A support element with adapter 10222A/8 (modifying guide 10-222 A/2115-14)
^ T10004 Two-hole pin wrench (or T10020)
^ T10172 Counter-bracket
^ T10172/4 Pin
Note: A new tensioning roller is gradually being introduced. The tensioning roller has an additional hex bit (arrow). Use a hex key to tighten/loosen toothed belt instead of the two-hole pin wrench T10020 or T10004. This does not change the work sequence.
Modifying guide 10-222A/21 from support device 10-222A
Support device 10-222A is required to support engine/transmission assembly.
A new hole is required on guide 10-222 A/21 to secure adapter 10-222 A18.
Dimensions given are in mm.
^ Drill a 12.5 mm diameter hole (arrow) in guide 10-222 A/21.
Removing
Note: Adjustment work on toothed belts must be performed on cold engines only. The tensioning element indicator position is dependent upon the engine temperature.
^ Remove engine cover.
^ Pull front of engine cover abruptly upward (arrow -A-) and then pull forward out of rear securing elements (arrow -B-).
^ Remove poly V-belt.
^ Remove poly V-belt tensioning element.
^ Remove coolant expansion tank (coolant hoses remain connected).
^ Remove fuel filter retaining plate.
^ Install engine support bracket 10-222A and take up weight of engine in its installed position.
^ Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body and assembly mounting/body mounting (arrows) and remove assembly mounting complete.
Note:
^ Remove engine mounting when the engine is secured with the support bracket 10-222A.
^ The engine mounting may only be loosened if the assembly mounting has been removed.
^ Remove toothed belt guard upper part.
^ Remove lower charge air pipe -1-.
^ Remove bolt/screw -2- and release connector (arrow).
^ Carefully cover or close open ends.
^ Remove center and right side sound insulation.
^ Unbolt engine mounting on cylinder block (arrows) and remove.
Note:
^ When loosening both upper engine mounting bolts the engine must be raised slightly with the support bracket.
^ When loosening the front engine mounting bolt the engine must be raised slightly with the support bracket.
^ Remove vibration damper/belt pulley.
^ Remove lower and middle toothed belt guards.
^ Set crankshaft to TDC No. 1 cylinder.
Note:
^ The engine may only be turned over using the crankshaft.
^ Turn crankshaft in direction of rotation until the marks on the crankshaft toothed belt sprocket are at the top and (arrow) "4Z" -2- on the toothed belt guard is aligned behind the tabs -1- of the wheel sensor.
^ In the illustration the camshaft toothed gear is shown without the toothed belt.
^ Lock hub using locking pin 3359. To do this, slide locking pin through free elongated hole on left side and into hole in cylinder head.
^ Lock crankshaft toothed belt gear using crankshaft stop T10050. To do this, slide crankshaft stop into teeth of sprocket from front of gear.
Note: Marks on crankshaft toothed belt gear -2- and on crankshaft stop -1- must align with one another. The pin of the crankshaft stop must engage in the hole in the sealing flange.
^ Mark direction of rotation of toothed belt.
^ Loosen camshaft sprocket securing bolts (arrows), until camshaft sprocket can be moved within elongated holes.
^ Loosen tensioning roller securing nut.
^ Turn tensioning roller counter-clockwise with two-hole pin wrench T10020 or T10004 until tensioning roller can be locked with pin T10115.
^ Turn tensioning roller with two-hole pin wrench T10020 or T10004 clockwise onto limit stop and tighten nut -1- by hand.
^ First remove toothed belt from coolant pump and then from remaining gears.
Installing
Requirements
^ Lock camshaft with pin 3359
^ Lock crankshaft with crankshaft stop T10050
^ Tensioning roller must be installed with pin T10115 and locked righthand.
Note: Adjustment work on toothed belts must be performed on cold engines only. The tensioning element indicator position is dependent upon the engine temperature.
^ Turn camshaft gear in elongated holes to centered position (arrow).
^ Place toothed belt on crankshaft pulley, tensioning roller, camshaft gear and idler roller.
^ Place toothed belt on coolant pump toothed belt gear last.
Note: Make sure that tensioning roller seats correctly in rear toothed belt guard (arrow).
^ Loosen tensioning roller securing nut and pull pin T10115 off.
^ Turn tensioning roller with two-hole pin wrench T10020 or T10004 clockwise until indicator aligns over tab in base plate (arrow).
^ Ensure that securing nut does not turn.
^ Hold tensioning roller in this position and tighten tensioning roller securing nut to 20 Nm plus an additional 45° (1/8 turn).
^ Insert counter-hold T10172 with pin T10172/4 as shown. Press counter-hold T10172 in direction of arrow and hold camshaft gear to pretension.
^ Tighten camshaft pulley securing bolts -1- in this position to 25 Nm.
^ Remove pin 3359 and crankshaft stop T10050.
^ Turn crankshaft two rotations in engine direction of rotation until crankshaft is set just before TDC No.1 cylinder.
^ Unlock hub with pin 3359 out of engine in direction of rotation .
^ Check whether crankshaft can be locked with crankshaft stop T10050.
If crankshaft will not lock:
^ Loosen camshaft pulley securing bolts (arrows).
^ Turn crankshaft slightly against engine direction of rotation until crankshaft stop pin is positioned just before hole in sealing flange (arrow).
^ Turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange while turning.
^ Insert counter-hold T101 72 with pin T101 72/4 as shown. Press counter-hold T101 72 in direction of (arrow) and hold camshaft gear to pretension.
^ Tighten camshaft pulley securing bolts -1- in this position to 25 Nm.
^ Remove pin 3359 and crankshaft stop T10050.
^ Turn crankshaft two rotations in engine direction of rotation until crankshaft is set just before TDC No. 1 cylinder.
^ Repeat check.
^ Install toothed belt guard center and lower parts.
^ Install belt pulley/vibration damper.
Tightening torque: 10 Nm plus an additional 90° (1/4 turn)
^ Install engine mounting to cylinder block and tighten (arrows).
Tightening torque: 45 Nm
Note:
^ Insert bolts into engine bracket before installing engine bracket.
^ Before installing the assembly mounting, all engine mounting bolts must be tightened to prescribed torque.
^ Install assembly mounting engine/body (replace securing bolts).
Tightening torque: 40 Nm plus an additional 90° (1/4 turn)
^ Align assembly mounting engine side.
^ Tighten engine mounting to engine bracket. When doing this put contact surfaces on workbench using support device 10-222A.
Tightening torque: 100 Nm
^ Install engine/body mounting.
Tightening torque: 25 Nm
^ Install toothed belt guard upper part.
^ Install fuel filter retaining plate.
^ Install coolant expansion tank.
^ Install poly V-belt tensioning element.
Tightening torque: 25 Nm
^ Install poly V-belt.
^ Install engine cover.
^ Install center and right side sound insulation.
^ Install lower charge air pipe.