Toothed Belt
Toothed Belt
• From 06.05 a revised engine mount bracket is being installed, which no longer requires that the engine mount bracket be removed and the engine be supported "Toothed Belt, Removing and Installing, Tensioning".
- Determine which engine mount bracket is installed in the vehicle.
- 1 -: engine mount bracket through 05.05 (removal required) => [ Toothed Belt, through 05.05 ].
- 2 -: engine mount bracket from 06.05 (removal not required) => [ Toothed Belt, from 06.05 ].
Toothed Belt, through 05.05
Special tools, testers and auxiliary items required
• Securing pin (3359)
• pin wrench (T10020)
• Securing pin (T10115)
• Crankshaft stop (T10050) for round crankshaft toothed belt gear
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• Engine support bridge (10 - 222 A)
• Adapter (10 - 222 A/3)
• Adapter (10 - 222 A/8)
• Spring-type clip pliers (VAS 5024A)
• Crankshaft stop (T10100) for oval crankshaft toothed belt gear
• counter-holder (T10172) with
• Adapter (10-222 A20)
Removing
• Adjustments to toothed belt may generally only be performed when the engine is cold, because the indicator position of the tensioning element changes depending on engine temperature.
- Remove engine cover.
One Piece Engine Cover
Pull the one piece front engine cover - arrows A - upward with a quick jerk and then pull the lower mount - arrow B - forward.
Two Piece Engine Cover
On the two piece engine cover, first pull the outer cover upward with a quick jerk - arrows in the upper illustration -, then pull the inner engine cover upward with a quick jerk - arrows in lower illustration -.
- Remove the connecting tube between the charge air cooler and intake connection.
- Remove coolant expansion tank. The hoses remain connected.
- Remove ribbed belt => [ Ribbed Drive Belt ] Ribbed Drive Belt.
- Remove the ribbed belt tensioning element.
- Remove the pin from the ribbed belt tensioning element.
- Remove the front rear wheel housing liner.
- Remove the charge air tube between the charge air cooler and turbocharger => [ Turbocharger Assembly Overview ] Turbocharger Assembly Overview.
• Seal off the openings of the charge air circuit carefully, e.g. with a clean cloth, to prevent the entry of dirt particles.
- Remove vibration damper.
- Unbolt the lower and middle toothed belt cover - arrows -.
- Attach the engine support bridge (10 - 222 A) with the frame (10 - 222 A/8) and adapter (10 - 222 A/3) and adapter (10 - 222 A/16) in front of the hood gas-filled strut.
- Hook the carabiner hooks of the spindles into the lifting eyes. Use the adapter (10 - 222 A/20) on the right side as well.
- Uniformly preload engine using both spindles, do not raise.
• If the toothed belt is removed for removing the cylinder head, mount the engine support bridge (10-222 A) with the higher adapters (10-222 A/13)=> [ Only Vehicles Through 05.05 ] Cylinder Head. This way there is enough space to remove the cylinder head.
- Unscrew the bolts - arrows - from the engine mount and remove the mount completely.
• The subframe may only be removed if the engine is supported by the engine support bridge (10 - 222 A)!
• The engine bracket may first be loosened only when the subframe is removed.
- Lift the engine with the engine support bridge (10 - 222 A) slightly so that both upper bolts - arrows - of the engine bracket can be loosened.
- Lower the engine using the engine support bridge (10 - 222 A) slightly so that the lower bolt - arrow - of the engine bracket can be loosened.
- Remove the refrigerant line mounting clamp from the longitudinal member.
- Remove the engine bracket to the rear and out.
- Turn crankshaft to set cylinder 1 at TDC.
• Phased in introduction of oval crankshaft toothed belt gears. If equipped with this toothed belt gear, it must be secured with the crankshaft stop (T10100) to determine TDC.
Crankshaft Toothed Belt Gear Identification
A = round toothed belt gear, secure with crankshaft stop (T10050), TDC marking at "12 o'clock"
B = oval toothed belt gear, secure with crankshaft stop (T10100), TDC marking at "1 o'clock"
• When doing so, turn the crankshaft so that the marking on the crankshaft toothed belt gear and the tooth segment of the camshaft gear are positioned upward. The marking on the rear toothed belt cover must align with the marking on the camshaft sensor wheel - arrow -.
- Lock the hub with the rig pin (3359). To do this, push the rig pin through the left sided empty slot in the bore of the cylinder head.
- Also, lock the toothed belt crankshaft sprocket with the crankshaft stop (T10100). Push the crankshaft stop from the front side of the toothed belt sprocket into the teeth.
• Markings on toothed belt crankshaft sprocket and the crankshaft stop must be aligned. The tab of the crankshaft stop must engage in the bore of the sealing flange.
- Mark rotational direction of toothed belt.
- Loosen the bolts - 1 - of the camshaft sprockets, until the camshaft sprocket can be turned in the slots.
- Loosen the nut of the tensioning roller.
• Phased in introduction of a new toothed belt tensioning roller. The tensioning roller has an additional internal hex - arrow -. To tension/relieve the toothed belt, use a internal hex key instead of the toothed belt tensioner (T10020). The work procedure does not change due to this.
- Turn the toothed belt tensioner (T10020) counterclockwise until the toothed belt tensioning roller can be locked with the locking pin (T10115).
- Turn the toothed belt tensioner (T10020) clockwise until the stop and then tighten the nut - 1 - by hand.
- First, take the toothed belt from the coolant pump and then from the remaining sprockets.
Installing
• Camshaft is secured with the rig pin (3359).
• Crankshaft is secured with crankshaft stop (T10050 bzw. T10100).
• Tensioning roller is secured with locking pin (T10115) and seated on right stop.
• Adjustments to toothed belt may generally only be performed when the engine is cold, because the indicator position of the tensioning element changes depending on engine temperature.
- Turn the camshaft sprocket in its slots - arrows - to middle position.
- Place the toothed belt onto the crankshaft sprocket, tensioning roller, camshaft sprocket and idler roller.
- Lastly, lay the toothed belt onto the toothed belt coolant pump sprocket.
• Make sure the tensioning roller is properly positioned in the rear toothed belt guard - arrow -.
- Loosen the nut of the tensioning roller and pull out the locking pin (T10115).
- Carefully turn the tensioning roller with the pin wrench (T10020) in clockwise direction, until the indicator is located centrally in the gap - arrow - of the base plate.
Make sure that the nut does not turn along with it.
- Hold the tensioning roller in this position and tighten the nut on the tensioning roller as follows: to 20 Nm and 45° (1/8 turn) additional.
- Install the counter-holder (T10172) with pins (T10172/4) as shown. Push the counter-holder (T10172) in - direction of arrow - and hold the camshaft sprocket pretensioned.
- In this position, tighten the camshaft sprocket bolts - 1 - to 25 Nm.
- Remove the rig pin (3359) and the crankshaft stop (T10050 bzw. T10100).
- Continue turning crankshaft two rotations in direction of engine rotation until the crankshaft is shortly before TDC for cylinder 1.
- Lock the hub with the rig pin (3359) from the rotating movement in engine rotation direction.
- Check if the crankshaft can be locked with the crankshaft stop (T10050 bzw. T10100).
If the crankshaft cannot be locked:
- Loosen the bolts - 1 - of the camshaft sprocket.
- Lock the hub with the rig pin (3359).
- Turn the crankshaft against the engine running direction until the crankshaft stop tab is positioned shortly before the sealing flange bore - arrow -.
- Now turn the crankshaft in engine running direction until the crankshaft stop tab engages the sealing flange.
- Install the counter-holder (T10172) with pins (T10172/4) as shown. Push the counter-holder (T10172) in - direction of arrow - and hold the camshaft sprocket pre-tensioned.
- In this position, tighten the camshaft sprocket bolts - 1 - to 25 Nm.
- Remove the rig pin (3359) and the crankshaft stop (T10050 bzw. T10100).
- Continue turning crankshaft two rotations in direction of engine rotation until the crankshaft is shortly before TDC for cylinder 1.
- Check again.
- Mount the engine mount bracket on the cylinder block and tighten the mounting bolts - arrows - to 40 Nm + 180° (1/2 turn) additional turn.
• Before the engine mount can be installed, all bolts - arrows - for the engine mount bracket must be tightened to specification.
- Install the engine mount/body (replace bolts) => [ Engine and Transmission Mount Tightening Specifications ] Engine and Transmission Mount Tightening Specifications.
- Fasten the engine mount to the engine mount bracket => [ Engine and Transmission Mount Tightening Specifications ] Engine and Transmission Mount Tightening Specifications. To do so, bring contact surfaces into contact using engine support bridge (10 - 222A).
- Install the lower and center toothed belt guard.
- Install the vibration damper. Tightening specifications: 10 Nm + 90° (1/4 turn) further
- Install ribbed belt => [ Ribbed Drive Belt ] Ribbed Drive Belt.
- Install upper toothed belt guard.
- Install the connecting tubes for charge air cooler/turbocharger and charge air cooler/intake connection => [ Turbocharger Assembly Overview ] Turbocharger Assembly Overview.
- Install the right front wheel housing liner.
- Install the coolant expansion tank => [ Cooling System Components Assembly Overview, Body Side ] Cooling System Components Assembly Overview, Body Side.
Toothed Belt, from 06.05
Special tools, testers and auxiliary items required
• Rig pin (3359)
• Drift (T10060 A)
• Crankshaft stop (T10100)
• Counter-holder tool (T10172)
• Socket wrench (T10264)
• Locking tool (T10265)
Removing
• Observe safety precautions => [ Fuel Supply System Safety Precautions ] Fuel Supply System Safety Precautions.
- Turn the ignition and all electrical consumers off and remove the ignition key.
- Remove engine cover.
One Piece Engine Cover
Pull the one piece front engine cover - arrows A - upward with a quick jerk and then pull the lower mount - arrow B - forward.
Two Piece Engine Cover
On the two piece engine cover, first pull the outer cover upward with a quick jerk - arrows in the upper illustration -, then pull the inner engine cover upward with a quick jerk - arrows in lower illustration -.
CAUTION!
• The temperature of the fuel lines as well as the fuel can, in extreme cases, go up to 100 °C on vehicles equipped with a PD engine. Before opening any line connections, let the fuel cool down otherwise you could get burned.
• Wear protective gloves.
• Wear safety glasses.
- Disconnect the fuel supply hose - 2 - and the fuel return hose - 1 - from the fuel lines.
- Disconnect the coolant line - 3 -.
- Remove bolts - 1 -.
- Remove the connecting pipe between the charge air cooler and the intake connection; while doing this, slightly lift the clips - arrows -.
- Disconnect the fuel supply line - 3 - and the fuel return line - 2 -; while doing this pull the release buttons.
Fuel Filter Without the Retaining Plate
- Release the clips and remove the fuel filter with the hoses still connected from the retaining plate - arrow -.
Fuel Filter With the Retaining Plate
- Loosen the bolt - 1 - one turn.
- Remove the bolt - 2 - and the nut - 3 -.
- Remove the fuel filter with the hoses still connected.
Continuation for All
- Remove the bolt on the fuel filler tube - 2 - for the washer fluid reservoir.
- Remove the retaining plate - 3 - for the fuel filter, if equipped.
- Disconnect the electrical connectors on the coolant expansion tank - 1 -.
- Remove coolant expansion tank with the hoses still connected. Lay it on the engine.
- Remove ribbed belt => [ Ribbed Drive Belt ] Ribbed Drive Belt.
- Remove the ribbed belt tensioning element.
- Remove the upper toothed belt guard; to do this, loosen the clips - arrows -.
- Remove front right wheel housing liner.
- Remove vibration damper/belt pulley.
- Remove the lower and center toothed belt guard.
- Turn crankshaft to set cylinder 1 at TDC.
• When doing so, turn the crankshaft so that the marking on the crankshaft toothed belt gear and the tooth segment of the camshaft gear are positioned upward. The marking on the rear toothed belt guard must align with the marking on the camshaft sensor wheel - arrow -.
- Lock the hub with the rig pin (3359). To do this, push the rig pin through the left-sided empty slot in the bore of the cylinder head.
- Also, lock the toothed belt crankshaft sprocket with the crankshaft stop (T10100). Push the crankshaft stop from the front side of the toothed belt sprocket into the teeth.
• Markings on toothed belt crankshaft sprocket and the crankshaft stop must be aligned. The tab of the crankshaft stop must engage in the bore of the sealing flange.
- Mark rotational direction of toothed belt.
- Loosen the bolts - 1 - of the camshaft sprockets, until the camshaft sprocket can be turned in the slots.
- Loosen the nut - 1 - of the tensioning roller.
- Turn the tension roller eccentric pulley using socket wrench (T10264) counterclockwise - arrow -, until the securing pin (T10265) can lock the tension roller.
- Now turn the tensioning roller eccentric pulley clockwise - arrow - all the way and tighten the nut - 1 - by hand.
- First, take the toothed belt from the coolant pump and then from the remaining toothed belt gears.
Installing
• Camshaft is secured with the rig pin (3359).
• Crankshaft locked with crankshaft stop (T10100).
• Tensioning roller secured with pin (T10265) and seated on right stop with the nut.
• Adjustments to toothed belt may generally only be performed when the engine is cold, because the indicator position of the tensioning element changes depending on engine temperature.
- Turn the camshaft sprocket in its slots - arrows - to middle position.
- Install the toothed belt through the space between the engine mount and the engine.
- Place the toothed belt onto the crankshaft sprocket, tensioning roller, camshaft sprocket and idler roller.
- Lastly, lay the toothed belt onto the toothed belt coolant pump sprocket.
• Make sure the tensioning roller is properly positioned in the rear toothed belt guard - arrow -.
- Pull the locking pin (T10265) out from the tensioning roller.
- Loosen the nut - 1 - of the tensioning roller.
- Turn the tensioning roller eccentric pulley using the socket wrench (T10264) clockwise - arrow -, until the indicator - 2 - is located centrally in the gap of the base plate.
• Make sure that the nut does not turn along with it.
- Hold the tensioner roller in this position and tighten the nut to 20 Nm + 45° (1/8 turn).
- Mount the counter-holder tool (T10172) with the bolt (T10172/4) as shown in the illustration, and hold the toothed belt tensioned by pushing in - direction of arrow -.
- Tighten the camshaft sprocket bolts - 1 - to 25 Nm.
- Remove the rig pin (3359) and the crankshaft stop (T10100).
- Turn the crankshaft 2 turns in the direction of the engine, until the crankshaft is once again just in front of TDC.
- Lock the hub with the rig pin (3359) from the rotating movement in engine rotation direction.
- Check if the crankshaft can be locked with the crankshaft stop (T10100).
If the crankshaft cannot be locked:
- Loosen the bolts - 1 - of the camshaft sprocket.
- Turn the crankshaft against the engine running direction until the crankshaft stop tab is positioned shortly before the sealing flange bore - arrow -.
- Now turn the crankshaft in engine running direction until the crankshaft stop tab engages the sealing flange.
- Install the counter-holder (T10172) with pins (T10172/4) as shown. Push the counter-holder (T10172) in direction of arrow and hold the camshaft sprocket pre-tensioned.
- In this position, tighten the camshaft sprocket bolts - 1 - to 25 Nm.
- Remove the rig pin (3359) and the crankshaft stop (T10100).
- Continue turning crankshaft two rotations in direction of engine rotation until the crankshaft is shortly before TDC for cylinder 1.
- Repeat the inspection and adjust if necessary.
- Install the lower and center toothed belt guard.
- Install the vibration damper/belt pulley. Tightening specifications 10 Nm + 90° (1/4 turn) further
- Install ribbed belt => [ Ribbed Drive Belt ] Ribbed Drive Belt.
- Install upper toothed belt guard.
- Install the connecting tube between the charge air cooler and intake connection.
- Install the front right wheel housing liner.
- Install the coolant expansion tank.
- Install the fuel filter.
- Tighten the filler tube for the windshield washer.
- Install the engine cover.