Removal and Replacement

Tooth Belt Removal and Installation

Special tools, testers and auxiliary items required
- Crankshaft Holder (3242)
- Puller (T40001)
- Camshaft Adjustment (T40005)
- Tightener Pulley Wrench (T40009)
- Locking Pin (T40011)
- Reversible Ratchet (VAS 5122)
- Torque Wrench (VAG 1410)
- Torque Wrench 5-50 Nm (VAG 1331)

Removing

CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.

Ensure sufficient clearance to all moving or hot components.

- Remove the noise insulation. Service and Repair
- Bring the lock carrier into the service position. Service and Repair
- Remove the crossmember.
- Remove the ribbed belt. Service and Repair
- Remove the left and right toothed belt covers.
- Set the crankshaft to Top Dead Center (TDC). The marking on the toothed belt guard - A - must be aligned with the notch on the pulley - B -.



- Check the position of the camshaft gears. The large holes - arrows - on the securing plates must align on the inside.



- If the large holes are on the outer side of the gears, the crankshaft must be turned one rotation again.
- Remove the locking bolt from the cylinder block - arrow -. The TDC hole for the crankshaft must be visible or felt inside the hole for the locking bolt.



- Carefully install the (3242) into the hole until seated, and thereby securing the crankshaft from turning.



- Remove the center toothed belt cover.
- Remove the vibration damper.
- The vibration damper is secured to the crankshaft toothed sprocket with 8 bolts.
- Remove the ribbed belt tensioner - 1 -.



- Remove the bolts - 2 - for the toothed belt tensioner element cover.
- Remove the cover.
- Mark the direction of rotation of the toothed belt.
- The toothed belt tensioner is oil dampened. Therefore it can only be compressed slowly.
- Use the (T40011) to secure the tensioner element.
- If necessary, align the plunger using needle nose pliers or thin wire before tensioning.
- Rotate the tensioner lever - 1 - in the - direction of arrow - using a hex wrench.
- When the tensioner lever pushes the tensioner element - 2 - together so that the holes in the housing and piston align, secure the tensioner element using the (T40011).



- Place the (T40005) into the securing plates for the camshafts and loosen the bolts approximately 5 turns.



- Remove the (T40005) again.
- Now remove the camshaft gears using the (T40001) and the (T40001/2).



- Loosen the eccentric roller bolt - arrow - and remove the toothed belt.




Installing
- On used toothed belts, observe the marking for the direction of rotation.
- Install the toothed belt onto the crankshaft toothed belt sprocket - 1 - first, then onto the tensioner roller - 2 - and then onto the eccentric roller - 3 -. Then, install it onto the camshaft gears and the coolant pump pulley as shown in the illustration.



- Camshaft gears must just be able to be twisted on the camshaft cones.
- Install the (T40005) onto the camshaft gears again.



- Install a 5 mm drill bit - arrow - between the tensioner lever and the piston of the tensioner element.



- Pretension the loosened eccentric roller using the (VAG 1410) with the (VAS 5122) connected with the (T40009) counterclockwise - arrow - to 4 Nm.



- In this position, tighten the bolt - 1 - to 45 Nm.
- Remove the 5 mm drill bit.
- Rotate the tensioner lever - 1 - in the - direction of arrow - using a hex wrench.
- When the tensioner lever has compressed the piston in the tensioner element - 2 -, pull out the (T40011).



- Turn the tensioner lever - 1 - in the - direction of arrow - using a hex wrench. Place a 7 mm drill bit between the tensioner lever and tensioner element.



- Tighten the camshaft gears to 55 Nm.
- Remove the (T40005) again.
- Remove the drill bit, that was inserted between the tensioner lever and tensioner element.
- Remove the (3242) from the hole, install the locking bolt with a new seal - arrow - and tighten to 35 Nm.



- Rotate the crankshaft twice in direction of engine rotation and check the adjustment dimension - a -. Specified value: 5 mm.



- Install the cover and ribbed belt tensioner roller. Tightening specification: 40 Nm
- The rest of the installation is basically a reverse of the removal sequence.