Timing Belt: Service and Repair

Toothed Belt

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Pin Wrench (3387)

• Marking Plate (T10008)

• Torque Wrench (V.A.G 1332)

Removing

- Bring lock carrier into service position. Refer to => [ Lock Carrier, Moving into Service Position ] Lock Carrier, Moving Into Service Position.

- Open quick-release fasteners - arrows - and remove the engine cover.





• Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the ribbed belt under operating conditions.

- Move the tensioning element in direction of - arrow - to release the tension on the ribbed belt.





- Remove ribbed belt.

- Remove bolts - arrows - and the ribbed belt tensioner.





- Remove upper toothed belt guard.





CAUTION!
Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

- Turn the crankshaft to TDC at the toothed belt pulley bolt.

• The markings on the crankshaft sprocket and on the crankshaft must be at TDC - arrows -.

- Remove vibration damper.





- Remove center and lower toothed belt guard - arrows -.





CAUTION!
• The toothed belt tensioner is oil-dampened and can be compressed by applying constant pressure.

• Excessive force will damage the toothed belt tensioner.

- Using a socket wrench, push the toothed belt tensioner with even, not excessive force counter-clockwise in direction of - arrow - until it is possible to secure the tensioner piston with the Marking Plate (T10008).





- Insert the Marking Plate (T10008) and leave it inserted.

• Stop tab - A - of eccentric must not be bent.





- To release the tension on the toothed belt, loosen nut - 1 - on the tensioner and turn the eccentric pulley with the Pin Wrench (3387) clockwise in direction of - arrow -.

- Identify direction of toothed belt travel with chalk or felt-tip pen.

- Remove toothed belt.

Installing (Adjusting valve timing)

• When performing repairs which require that the toothed belt be removed only from the camshaft sprocket, then the toothed belt must be adjusted as following:

• When turning camshaft, crankshaft must not be at TDC with any cylinder. Valves and/or pistons may be damaged.

- Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).

- Install lower toothed belt guard.

• The vibration damper/belt pulley can only be installed in one position. The vibration damper crankshaft hole - arrow - must be positioned over the protrusion on the toothed belt sprocket for the crankshaft.





- Secure the Vibration damper/belt pulley, observe locating point - arrow -.

- Bring the markings on the camshaft sprocket to the cylinder head cover and the markings on the vibration damper to the toothed belt guard so that they meet - arrows -.





- Make sure the toothed belt tensioner is secured with the Marking Plate (T10008).

- Place toothed belt on coolant pump, tensioning roller and camshaft gear (in this order).

Tensioning the toothed belt

• Stop tab - A - of eccentric must not be bent.





- Rotate eccentric pulley using the Pin Wrench ( 3387) counter-clockwise in direction of - arrow -.

- Hold the eccentric pulley in this position and remove the Marking Plate (T10008).

- Rotate the eccentric pulley clockwise far enough in direction of - arrow - until it is possible to pull the a gauge - 2 - - a - = 8 mm (for example, a drill) between the tensioning lever and the tensioner housing.





- Hold the eccentric pulley in this position and tighten the nut - 1 - with the tensioner roller to 27 Nm.

CAUTION!
Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

- Turn crankshaft 2 turns using the bolt for the toothed belt pulley until the piston is at TDC.





• The markings on the crankshaft sprocket and on the crankshaft must be at TDC - arrows -.

- Check dimension - a - between the tensioning lever and the tensioner housing using a drill bit - 2 -.





• Dimension - a - = 6 to 10 mm.

If dimension - a - is not obtained:

CAUTION!
• The toothed belt tensioner is oil-dampened and can be compressed by applying constant pressure.

• Excessive force will damage the toothed belt tensioner.

- Using a socket wrench, push the toothed belt tensioner with even, not excessive force counter-clockwise in direction of - arrow - until it is possible to secure the tensioner piston with the Marking Plate (T10008).





- Loosen nut - 1 - of the tensioning roller.





- Tension toothed belt.

If dimension - a - is obtained:

- Install the center and upper toothed belt guard.

Assembling

Assembly is in reverse order of removal, note the following:

- Install ribbed belt tensioning element - arrows -.





- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Install upper toothed belt guard while carefully engaging the center toothed belt guard.

- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support

- Place the torque support stop on the rubber buffer and tighten the nuts - arrows -.





- Install front bumper cover.

- Check headlamp adjustment.

Tightening Specifications





* Insert using locking compound

* Replace bolts.

* 90° corresponds to one quarter rotation.