Timing Belt Tensioner: Service and Repair

Camshaft drive belt, removing, installing and tensioning
(Adjusting timing)





Special tools and equipment
^ 10-222A Engine support bridge 10-222A/8 engine support feet.
^ T 10020 Toothed belt tensioner
^ VAG1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft. lbs.) (or equivalent)
^ VAG1332 Torque wrench 40 to 200 Nm (30 to 148 ft. lbs.) (or equivalent)

10-222 A/21 guide from 10-222 A support tool, modifying
Use 1 0-222A support tool to support engine/transmission.





- Drill a new hole to fasten 10-222 A/8 adapter to 10-222 A/21 guide.
Dimensions are in mm.
- 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 damper to cyl. 1 TDC -arrows-.
- Remove coolant expansion tank and place to side. (hoses remain connected)
- 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 1 0-222A/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
If camshaft drive belt only has been removed from camshaft, Refer to Timing Belt Service and Repair, Camshaft drive Belt.
Condition
^ 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. lbs.)

Note: Insert screws before installing engine support.

- Install camshaft drive belt guard center and lower sections.





- Install vibration damper/belt pulley. Tightening torque: 40 Nm (30 ft. lbs.)





- Turn crankshaft to cyl. 1 TDC -arrows-.
- Install engine mounts (replace bolts).
- Align engine and transmission mounts, Refer to Engine Mount, Service and Repair

Note: Tightening torques for mounts, Refer to Engine Mount, Specifications, Mechanical
- Install coolant expansion tank. Torque to 7 Nm (5 lb ft).
- Install vacuum pipes at EVAP canister and at throttle valve housing.
- Place camshaft drive belt on tensioning roller and camshaft sprocket and tension, Refer to Timing Belt, Service and Repair, Camshaft drive belt Tensioning.
- Remove 10-222 A support.

B - Camshaft drive belt, removed from camshaft sprocket only
Condition
^ 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 not 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 2-hole pin wrench T 10020 onto stop.
- Tension is correct when notch -1- and indicator -2- align. (Check using mirror).
- Tighten securing nut to 20 Nm (15 ft. lbs.)
- 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. lbs.)
- Install ribbed belt.
- Install sound dampening pan and engine cover.