Timing Belt: Service and Repair
Toothed belts, removing, installing and tensioning
Special tools, testers and auxiliary items required
^ Locking pin 3359
^ Pin wrench 3387
^ Locking pin T10115
^ Crankshaft stop T10050
^ Torque wrench (5...50 Nm) V.A.G 1331
^ Torque wrench (40...200 Nm) V.A.G 1332
^ Support device 10-222A with legs 10-222A/1
Removing
Note: Perform adjustment work on toothed belts on cold engines only.
- Remove poly V-belt.
- Remove tensioning element for poly V-belt.
- Remove right headlight.
- Remove charge air pipe between charge air cooler and exhaust turbocharger.
- Remove coolant expansion tank (coolant hoses remain connected).
- Unbolt power steering reservoir and fuel filter and set aside (hoses remain connected).
- Disconnect fuel lines from cylinder head cover.
CAUTION!
^ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
^ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen the connection to release the pressure!
^ Wear eye and hand protection when performing any type of repair work on the fuel system!
- Mount 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:
^ The assembly mounting may only be removed, if the engine is supported with support device 10-222A!
^ The engine mounting may only be loosened if the assembly mounting has been removed.
- 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 device.
^ When loosening the lower engine mounting bolt the engine must be lowered slightly with the support device.
- Remove vibration damper/belt pulley.
- Remove center and lower toothed belt guard.
- Turn crankshaft to TDC No. 1 cylinder.
Note: Turn the crankshaft so far that the marking on the crankshaft sprocket is at the top and the arrow on the rear toothed belt guard aligns with the lugs on the sender wheel of the hub - arrows -.
- Lock hub with locking pin 3359. To do this, slide locking pin through free elongated hole on left side of cylinder head.
- Lock crankshaft pulley with crankshaft stop T10050. To do this, push crankshaft stop from face side of toothed belt pulley into pulley teeth.
Note: The marks on the crankshaft pulley and the crankshaft stop must align. At the same time, the pin of the crankshaft stop must engage in the hole in the sealing flange.
- Mark direction of rotation of toothed belt.
- Loosen tensioning roller securing nut.
- Loosen camshaft pulley securing bolts - 1 - until camshaft pulley can be moved within elongated holes.
- Turn pin wrench 3387 counter-clockwise (opposite direction of arrow on tensioner) until toothed belt tensioner can be locked in position using locking pin T10115.
- Turn pin wrench clockwise (in direction of - arrow - on tensioner) until stop and tighten securing nut hand-tight.
- Remove toothed belt first from coolant pump and then from remaining pulleys. Installing
Note:
^ Adjustment work on toothed belts must only be performed on cold engines as the indicator on the tensioning element alters depending on the engine temperature.
^ The tensioning roller must be locked with locking pin T10115 and secured to the right limit stop.
- Turn camshaft pulley in elongated holes counter-clockwise - in direction of arrow - onto limit stop.
- Install toothed belt to crankshaft pulley, belt tensioner and camshaft pulley.
- Install toothed belt onto coolant pump toothed belt pulley.
Note: Ensure that tensioning roller seats correctly in rear toothed belt guard - arrow -.
- Loosen tensioning roller securing nut.
- Relieve tension on tensioning roller by turning pin wrench in opposite direction of - arrow - and remove locking pin from tensioning roller.
- Carefully turn tensioning roller with pin wrench 3387 in direction of arrow until indicator is in middle of gap in base plate - arrow -.
- Hold tensioning roller in this position and tighten tensioning roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
- Tighten camshaft pulley securing bolts to 25 Nm.
- Remove locking pin 3359 and crankshaft stop T10050.
- Turn crankshaft two rotations in direction of engine rotation and set again to TDC No. 1 cylinder.
Note:
^ ^ As this is done, the shaft of the crankshaft stop must be able to engage in the sealing flange from direction of engine rotation.
^ If the crankshaft is turned past TDC No. 1 Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in the direction of engine rotation again to set it to TDC No. 1 cyl. It is not permitted to turn the engine opposite to the normal direction of rotation when turning to ensure the crankshaft stop will engage.
- Once crankshaft stop T10050 has engaged, check whether hub can be fixed in place using locking pin 3359.
If the hub cannot be locked:
- Pull crankshaft stop pin out of hole in sealing flange and turn crankshaft until hub can be locked with locking pin.
- Loosen camshaft pulley securing bolts - 1 -.
- Turn crankshaft slightly against direction of engine 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.
- Tighten camshaft pulley securing bolts to 25 Nm.
- Remove locking pin 3359 and crankshaft stop T10050.
- Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
Note:
^ As this is done, the shaft of the crankshaft stop must be able to engage in the sealing flange from direction of engine rotation.
^ If the crankshaft is turned past TDC No. 1 Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in direction of engine rotation again to set it to TDC No. 1 cyl. It is not permitted to turn the engine opposite to the normal direction of rotation when turning to ensure the crankshaft stop will engage.
- Repeat check.
- Install lower toothed belt guard and vibration damper/belt pulley.
- Install center toothed belt guard.
- Install engine mounting to cylinder block and tighten - arrows -. Tightening torque: 45 Nm
- Install top toothed belt guard.
Note: Before installing the assembly mounting, all engine mounting bolts must be tightened to prescribed torque.
- Install engine/body assembly mounting (replace securing bolts). Tightening torque: 40 Nm plus an additional 90° (1/4 turn).
- Align engine and transmission mountings.
- Tighten engine assembly mounting to engine bracket. Use support device 10-222 A to bring contact surfaces into position. Tightening torque: 100 Nm
- Install bracket for body assembly mounting. Tightening torque: 25 Nm
- Install coolant expansion tank.
- Install power steering reservoir and fuel filter.
- Install charge air pipe between charge air cooler and intake connecting flange.
- Install poly V-belt tensioning element. Tightening torque: 25 Nm
- Install poly V-belt.
- Install right side insulation tray.
- Install sound insulation tray.