Removal and Replacement
Toothed belts, removing, installing and tensioning
Engine: BBW
(Adjusting valve timing)
Special tools and equipment
^ 10-222A Engine support bracket with legs 10222A/1
^ 2065 A Adjustment bar
^ V.A.G. 1331 Torque wrench (5 to 50 Nm)
^ V.A.G. 1332 Torque wrench (40 to 200 Nm)
^ T10004 Two hole pin wrench
^ T10172 Counter-bracket
Special tools and equipment
^ T101 72/3 Pin
Note:
^ If the toothed belt is to be taken off the camshaft sprocket, e.g. when removing the camshaft or the cylinder head, the following must be considered:
^ Engine bracket, tensioning element for ribbed belt, vibration damper/belt pulley and toothed belt guard (except for upper part) can remain installed.
^ To remove the toothed belt from the camshaft sprocket, unscrew the tensioning roller and slide up to the engine bracket.
Counter tool T101 72
- Unscrew pins T101 72/1.
- Screw pins T10172/3 in and tighten.
Removing
- Remove engine cover.
- Remove right side sound insulation.
- Remove poly V-belt.
- Remove tensioning element for poly V-belt.
- Remove intake manifold upper part.
- Remove toothed belt guard upper part.
- Remove coolant expansion tank (supply hose remains connected, close union for return supply hose).
- Remove power steering reservoir (hoses remain connected).
- Disconnect connector of camshaft timing adjustment valve.
- Remove cylinder head cover.
- Mount support 1 0-222A with legs 1 0-222A/1 as shown.
- Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body, and assembly mounting bracket/body (arrows) and remove assembly mounting complete.
Note:
^ Only remove the engine mounting when the engine is secured with the support bracket 10-222A.
^ The engine bracket must be only released when the engine mounting is removed.
- Remove vibration damper/belt pulley.
- Remove engine bracket from cylinder block.
Note: When loosening the front engine mounting bolt the engine must be raised slightly with the support device.
- Remove toothed belt guard center and lower parts.
- Mark direction of rotation of toothed belt.
- Turn crankshaft until camshaft is set to TDC No. 1 cylinder.
Adjustment bar 2065 A must be pushed into slot of camshaft.
- Remove tool.
- Release tensioner and take off toothed belt.
- Turn crankshaft against engine direction of rotation 45°.
Installing
Requirements
- Pistons must not be positioned at TDC.
- Engine must only be hand touch warm.
Tensioning toothed belt and adjust valve timing
Note:
^ When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
^ Never use the adjustment bar 2065 A as counter-hold when loosening and tightening the camshaft sprocket! Use counter-bracket T10172 with pin T10172/3.
- Place a flat container under camshaft sprocket to collect oil leaking out when sealing plug -1- is loosened.
- Unscrew sealing plug -1- carefully and collect leaking oil. Do not rotate crankshaft, if possible.
Note: To loosen the sealing plug use counter-bracket T10172 with pin T10172/3, if necessary.
- Clean oil from camshaft sprocket with a cloth.
- Remove camshaft pulley bolt. Do not rotate crankshaft, if possible.
- To loosen the camshaft bolt use counter-bracket T101 72 with pin T10172/3.
- Take camshaft sprocket off camshaft and clean it.
Note:
^ The teeth on the crankshaft and the crankshaft seal contact surface must be free of oil.
^ In this condition, it is recommended to replace the crankshaft seal as a preventative and inexpensive measure.
- Install camshaft sprocket again and camshaft bolt.
- Set camshaft to TDC No. 1. Cyl. and insert adjustment bar 2065 A.
- Loosen camshaft bolt until camshaft sprocket can be turned by hand. Use counter-bracket T101 72 with pin T101 72/3.
- Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation).
- Install toothed belt guard center and lower parts and belt pulley/vibration damper.
- Turn crankshaft in engine direction of rotation again at TDC No. 1 Cyl.
- Notch -2- on belt pulley/vibration damper must align with notch -1- on toothed belt guard, upper part.
- Turn camshaft sprocket so that counter-bracket T101 72 with pin T101 72/3 can be inserted.
- Place toothed belt on tensioning roller and camshaft sprocket.
- Turn tensioning roller on eccentric with two hole pin wrench (T10004) five times onto limit stop in both directions.
- Tension toothed belt by turning eccentric to left (direction of arrow) with two hole pin wrench (T10004) onto limit stop.
- Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).
- Tighten securing nut to 20 Nm.
- Check TDC of crankshaft again, correct if necessary.
Note: If the crankshaft is positioned after TDC No. 1 cylinder turn the crankshaft again a bit against the engine direction of rotation and set to TDC No. 1 cylinder.
- Hold crankshaft sprocket with counter-bracket T101 72 (pin T10172/3) and tighten camshaft bolt to 40 Nm.
- Remove setting bar 2065 A.
- Counter-hold camshaft sprocket and tighten camshaft bolt to 130 Nm.
- Turn crankshaft two rotations in engine direction of rotation until setting bar 2065 A can be inserted.
Note:
^ It is essential that the last 45° is performed without stopping.
^ If the crankshaft has been turned to far, turn the crankshaft 1/4 turn back and set the camshaft to TDC No. 1 cylinder again (insert the setting bar 2065 A).
- Check TDC of crankshaft.
Notch -2- on vibration damper/belt pulley must be positioned -a- (max. 5 mm) after TDC marking -1- on toothed belt guard lower part.
If the crankshaft is not in this area:
- Repeat adjustment.
- If the crankshaft is in this area:
- Check toothed belt tension again and adjust if necessary.
Specification: Indicator and notch align
Continuation, install toothed belt complete
- Install sealing plug -1- (replace O-ring).
Tightening torque: 25 Nm
- Install engine mounting to cylinder block.
Tightening torque: 45 Nm
Note:
^ Insert bolts into engine bracket before installing engine bracket.
^ Tighten all bolts of the engine bracket, with the tightening torque mentioned, before installing the engine mounting.
- Install engine assembly mountings complete.
- Align assembly mountings for engine and transmission.
- Remove engine support device 10-222 A.
- Install toothed belt guard upper part.
- Install poly V-belt tensioning element.
Tightening torque: 25 Nm
- Install poly V-belt.
- Install coolant expansion tank.
- Install power steering reservoir.
- Install cylinder head cover.
- Connect connector of camshaft timing adjustment valve.
- Install intake manifold upper part.
- Start engine and run briefly at idling speed (oil pressure increase in camshaft adjustment).
- Install right side sound insulation:
- Check engine oil level and top off, if necessary.
- Install engine cover.