Toothed Belt
Toothed Belt
Special tools, testers and auxiliary items required
• Tightener pulley wrench (T40009)
• Crankshaft holder (3242)
• Torque wrench (5-60 Nm) (VAG 1783)
• Ratchet insert 1/4" (VAS 6234)
• Puller (T40001) with claws (T40001/2)
• Camshaft adjustment (T40005)
• Locking pin (T40011)
• Spanner wrench (3212)
Removing
• Before raising the vehicle on a hoist (wheels off the ground), activate the vehicle lift mode.
- Remove the front bumper.
- Remove the lock carrier.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the engine cover - 2 - upward.
- Remove the upper left and upper right toothed belt guards.
CAUTION!
Only turn over the engine at the crankshaft in the direction of engine rotation (clockwise).
- Rotate the crankshaft in the direction of engine rotation using the crankshaft toothed belt gear bolt to the cylinder 5 Top Dead Center (TDC) marking.
• Notch - B - aligns with the mark - A -
• Turning over the engine is performed at the center bolt of the crankshaft.
- Check the position of the camshafts:
• The large holes - arrows - on the securing plates of the camshaft gears must align on the inside.
- In case they do not align, turn one more rotation.
- Remove the coolant pipe bolt - arrow - from oil pan.
- Remove the coolant pipe bolt - arrow - from the engine block.
- Remove the locking bolt - arrow - for the TDC mark.
• In the crankshaft, a TDC bore is located exactly behind the locking bolt (can be felt by touch).
CAUTION!
Do not rotate the crankshaft while touching the TDC mark with your finger - danger of injury.
- Install the (3242) in the hole for the locking bolt in the upper oil pan.
- Remove the vibration damper bolts - 1 - from the crankshaft.
- Remove the center toothed belt guard.
- Remove the torque support bolt - arrow - from the torque support valve (N382).
- Remove the bracket bolts - arrows - for the torque support valve.
- Using an 8 mm hex wrench, rotate the toothed belt tensioner in the - direction of the arrow - until the tensioning lever pushes the tensioning element together far enough so that the (T40011) can be inserted into the bore of the tensioning element piston and housing.
• When inserting, the bracket for the torque support valve remains installed. The (T40011) can be guided through a hole in the bracket to be inserted into the holes in the tensioner.
• The toothed belt tensioner is oil dampened. Compress it by slowly applying constant pressure.
• Mark the direction of rotation of the toothed belt. Reversed running direction can cause damage.
- Loosen the eccentric roller bolt - arrow -.
- Install the (T40005) in the camshaft securing plates.
- Loosen both camshaft gear bolts approximately 5 turns.
• The (T40005) serves as a retainer.
- Remove the (T40005).
- Remove the left and right camshaft gears using the (T40001) with the (T40001/2).
- Remove the toothed belt.
CAUTION!
Check the gears after removing. If dents are visible, replace the gears.
Installing, (Adjusting Valve Timing)
• When turning the camshaft, the crankshaft must not be at TDC. Valves and/or pistons may be damaged.
- Replace the bolts - 1 - for the camshaft gears and securing plates - 2 -.
- Grease the threads and head seating surfaces of the bolts for the camshaft gears.
- Install the bolts far enough so that they can still just be turned and do not tilt.
- Observe the proper seating of the securing plates on the camshafts.
Before installing the toothed belt, make sure the crankshaft and camshafts are set to TDC cylinder 5:
• The large holes - arrows - on the securing plates at the camshaft gears must align on the inside.
• The (3242) must be installed in the hole in the upper oil pan.
- Route the toothed belt in the following sequence: Crankshaft toothed belt gear - 5 -, eccentric roller - 4 -, tensioner - 6 -, left camshaft gear - 3 -, coolant pump - 2 -.
- Lastly, place the toothed belt on the right camshaft gear - 1 -.
- Turn the tensioning lever twice at 40 Nm in the - direction of the arrow - to pretension the toothed belt.
• The next two illustrations are shown with the torque support bracket removed.
- Insert a 5 mm hex wrench flat between the tensioning lever - 1 - and tensioning element piston - 2 -.
- Tighten the toothed belt by turning the eccentric roller using the (T40009) and the (VAG 1783) using the (VAS 6234) in the - direction of the arrow - and hold.
• Pre-tightening specification: 6 Nm
- Tighten the eccentric roller bolt.
• Make sure that the position does not change while tightening.
- Insert the (T40005) into the securing plates of both camshafts.
• Press in the (T40005) as far as possible.
- Tighten the camshaft gears.
• The (T40005) serves as a retainer.
- Remove the (T40005).
- Remove the 5 mm hex wrench.
- Rotate the tensioning lever using a 8 mm hex wrench in the - direction of the arrow - until the (T40011) can be removed.
- Remove the (3242).
- Turn the crankshaft two complete rotations in direction of engine rotation until the crankshaft is at TDC cylinder 5 again.
• The large holes - arrows - on the securing plates for the camshaft gears must align on the inside.
- Check dimension - a - between the tensioning lever and tensioning element.
• Dimension - a - = 5.0 ± 1.0 mm
• If dimension - a - is not obtained, repeat the adjustment.
- To check the timing, install the (3242) in the hole in the upper oil pan again.
- Check the camshaft positions using the (T40005).
• If the (T40005) cannot be inserted, repeat adjustment.
- Remove the (T40005).
- Remove the (3242).
- Install the locking bolt of the TDC marking into the upper oil pan using new sealing ring.
Further installation is performed in reverse order of removal, noting the following:
• Replace the gaskets, seals and O-rings.
• Secure all hose connections using hose clamps appropriate for the model type.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the lock carrier with attachments.
- Fill the cooling system. Refer to => [ Draining and Filling ] Procedures.
- Install the torque support. Refer to => [ Torque Bracket and Support Valve Assembly Overview ] Torque Bracket and Support Valve Assembly Overview.
• Only reuse the drained coolant if the cylinder head or engine block was not replaced.
• Dirty coolant must not be reused.
Tightening Specifications
