Timing Belt Tensioner: Service and Repair

Toothed belt, removing, installing and tensioning





Special tools, workshop equipment, test and measuring appliances and aux. items required
^ 10-222A Engine support bracket with 10-222A/8 adapter
^ 3180 Retainer (for turbocharged engines)
^ T10092 Tensioning bolt
^ T40011 Locking pin
^ VAG1331 Torque wrench (5 to 50 Nm)
^ VAG1332 Torque wrench (40 to 200 Nm)
^ D 000 600 A2 Locking fluid

Removing
- Note safety precautions before starting work
- Observe rules for cleanliness.
- Remove engine cover.
- Remove right-hand insulation tray.





- Remove air duct to charge air cooler at bottom right of long member.
- Remove ribbed belt.
- Remove tensioning element for ribbed belt.
Engine installed:





- Turn crankshaft to TDC No. 1 cylinder (vehicles with manual transmission).





- Turn crankshaft to TDC No.1 cylinder (vehicles with automatic transmission).
With engine removed:





- Turn vibration damper to TDC No. 1 cylinder -arrows-.
- Remove coolant expansion tank and place to side.
- Pull off vacuum pipes at EVAP canister and at throttle valve housing.
- Remove toothed belt guard (upper part).





- Install engine support bracket 10-222A with legs 10-222A/1.
- Locate bracket 3180 in lifting eye on cylinder head and take-up weight of engine.





- Remove securing bolts from assembly mount engine mount, assembly mount/body and assembly mount/body mount -arrows- and remove assembly mount complete.





- Remove vibration damper/belt pulley.
- Remove lower and center toothed belt guard.





- Remove engine bracket from cylinder block.

Note: When loosening the front engine mount bolt the engine must be raised slightly with the support bracket.

- Mark direction of rotation of toothed belt.





- Screw tensioning bolt T10092 into toothed belt tensioning element.
- Align pressure piston using pointed pliers or wire before tensioning (hole in pressure piston must align with hole in housing).
- Tension piston of tensioning element just enough that the piston can be locked with locking pin T40011.
- Remove toothed belt.
- Turn crankshaft back slightly.

Installing

Note: When turning the camshaft the crankshaft must not be at TDC (danger of damage valves/piston crown).

A - Toothed belt completely removed
If toothed belt has only been removed from camshaft.

Conditions
^ The pistons must not be positioned at TDC





Work sequence
- Bring mark on camshaft in line with the mark on cylinder head cover.
- Place toothed belt on crankshaft sprocket (observe direction of rotation).
- Fit engine mount to cylinder block.
Tightening torque: 45 Nm

Note: Before installing engine mount, insert bolts into mount.

- Install lower part of toothed belt guard. (Insert securing bolts with locking fluid "D 000 600 A2".).
Tightening torque: 10 Nm
- Secure vibration damper/belt pulley with one bolt (note fixing arrangement).





- Turn crankshaft to TDC No. 1 cylinder.
- Install toothed belt onto coolant pump, tensioning roller and camshaft sprocket.
- Tighten toothed belt.





B - Toothed belt only taken off camshaft sprocket
- Bring mark on camshaft in line with the mark on cylinder head cover.
- Turn crankshaft to TDC No. 1 cylinder.
- Install toothed belt onto camshaft sprocket.
- Tighten toothed belt.





Tensioning toothed belt
- Tension toothed belt by pulling out locking pin T40011 and removing tensioning bolt T10092.
- Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference points.
- Install vibration damper/belt pulley
Tightening torque: 25 Nm
- Install center part of toothed belt guard. (Insert securing bolts with locking fluid D 000 600 A2).
Tightening torque: 10 Nm
- Install upper toothed belt guard.
- Install aggregate mount and engine mount.
- Install ribbed belt tensioner.
Tightening torque: 25 Nm
- Install ribbed belt.
- Install air duct to charge air cooler at bottom right of long member.
- Install right-hand insulation tray