Timing Belt: Service and Repair
Toothed Belt, Removing and Installing
Special tools, testers and auxiliary items required
• Engine support bridge (10-222 A)
• Pin wrench (T10020)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
Special tools, testers and auxiliary items required
• Engine Support Basic Set (T40091)
Perform the following:
Removing
- Remove the noise insulation.
- Remove ribbed belt => [ Ribbed Belt, Removing and Installing ] Service and Repair.
- Remove the ribbed belt tensioning damper.
- Remove the coolant reservoir. The coolant hoses remain connected.
- Remove the upper toothed belt guard.
- Turn the crankshaft the direction of engine rotation and move the camshaft sprocket to TDC cylinder 1.
• The marking on camshaft sprocket must line up with the arrow on toothed belt guard - arrows -.
- Remove the plenum chamber cover.
- Remove the radiator grille.
- Mount the engine support bridge (10 - 222 A) and support the engine in its installed position.
1. (T40091/3)
2. (10-222 A /31-1)
3. (10-222 A /12)
4. (10-222 A /3)
5. (10-222 A /31-4)
6. (10-222 A /31-3)
7. (T40091/1)
8. (10-222 A /18)
9. (10-222 A /31-2)
- Remove the engine mount bolts - arrows -.
- Remove the engine mount.
- Remove the belt pulley/vibration damper.
- Remove the engine support from the cylinder block.
• To loosen the front engine carrier bolt, the engine must be slightly lifted by the engine support bridge.
- Remove the lower and center toothed belt guards.
- Mark direction of rotation of toothed belt.
- Loosen the tensioning roller and remove the toothed belt.
- Then turn the crankshaft slightly backward.
Installing
Requirements
Danger of causing damage to the pistons and the valves.
• When turning camshaft, pistons may not be at TDC for any cylinder.
• The engine must be no more than warm to touch.
- Route the toothed belt over toothed belt sprocket for the crankshaft and coolant pump. Pay attention to the rotation direction of the toothed belt.
• With engine removed: Install the lower toothed belt guard as well as the belt pulley/vibration damper beforehand.
- Align marking on camshaft sprocket with marking on the toothed belt guard.
Engine installed:
- Turn the crankshaft in direction of engine rotation to the upper TDC cylinder 1.
• Vehicles with a manual transmission
• Vehicles with an automatic transmission
Engine removed:
- Turn the belt pulley/vibration damper in direction of engine rotation to upper TDC cylinder 1- arrows -.
Continued for all
- Lay toothed belt on tensioner and camshaft gear.
- Turn the tensioning roller by the eccentric pulley using the pin wrench (T10020) , 5 times all the way in both directions.
- Tension the toothed belt. Turn the pin wrench (T10020) on the eccentric pulley all the way to the left in - direction of arrow -.
- Then release the tension on the toothed belt until the notch - 1 - and the pointer - 2 - are opposite each other. Use a mirror.
- Tighten the nut.
Tightening specification: 20 Nm
- Turn crankshaft over twice in engine running direction and then set cyl. 1 to TDC again.
• For this it is necessary that the last 45° (1/8 rotation) is turned without interruption.
- Check tension of toothed belt again.
• Specified value: The pointer and the notch must be opposite each other.
If the tension on the ribbed belt is OK:
- Install the lower and center toothed belt guards.
- Install the belt pulley/vibration damper.
Tightening specification: 25 Nm
- Attach the engine support to the cylinder block.
Tightening specification: 45 Nm
• Install the bolts into the engine support before installing it.
- Install the engine mount.
- Align engine and transmission mountings => [ Subframe Mount, Adjusting ] Subframe Mount, Adjusting.
• For the subframe mount tightening specifications, refer to => [ Subframe Mount Tightening Specifications ] Subframe Mount Tightening Specifications.
- Remove engine support bridge (10 - 222 A).
- Install the upper toothed belt guard.
- Install the ribbed belt tensioning element.
Tightening specification: 23 Nm
- Install the ribbed belt. Refer to => [ Ribbed Belt, Removing and Installing ] Service and Repair.
The further installation is performed in reverse order of removal.