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Home >> Volkswagen >> 2006 >> Golf (1J1) L4-2.0L (AVH) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Timing Belt >> Service and Repair >> Removal and Replacement

Removal and Replacement



Toothed belts, removing, installing and tensioning





^ Engine codes AEG, AVH, AZG, BEV

Special tools and equipment
^ 10-222A Engine support bracket with legs 10-222A/1
^ T10004 Two hole pin wrench
^ V.A.G 1331 Torque wrench (5 to 50 Nm)
^ V.A.G 1332 Torque wrench (40 to 200 Nm)

Removing
- Remove engine cover.
- Remove right side sound insulation.
- Remove poly V-belt.
- Remove tensioning element for poly V-belt.
- Remove coolant expansion tank (supply hose remains connected, close union for return supply hose).
- Remove power steering reservoir (hoses remain connected).
- Remove toothed belt guard upper part.





- Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft pulley must align with (arrow) on toothed belt guard.





- Mount support 10-222A with legs 10-222A/1 as shown.





- Remove securing bolts from assembly mounting/engine bracket, assembly mounting/body and assembly mounting bracket/body (arrows) and remove assembly mounting complete.





- Remove vibration damper/belt pulley.





- Remove engine bracket from cylinder head.

Note:
- When loosening the front engine mounting bolt the engine must be raised slightly with the support device.

- Remove toothed belt guard center and lower parts.
- Mark direction of rotation of toothed belt.
- Release tensioner and take off toothed belt.
- Turn crankshaft back slightly.

Installing

Requirements
^ Pistons must not be positioned at TDC.

Work sequence
- Place toothed belt on crankshaft pulley and coolant pump pulley (observe direction of rotation).

Note:
- With engine removed:

- Install lower toothed belt guard and vibration damper/belt pulley.

Adjusting valve timing

Note:
- When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.





- Align mark on camshaft with mark on toothed belt cover.

Engine installed:





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





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

With engine removed:





- Position vibration damper at TDC No. 1 cylinder (arrows).
- Installed toothed belt on tensioning roller and camshaft pulley.

Tensioning toothed belt

Requirements
^ Engine must be no more than warm to the touch.
^ Camshaft pulley positioned at TDC for cylinder 1.
^ Before tensioning toothed belt, turn tensioning roller 5 times on to limit stop (in both directions) at eccentric using pin wrench T10020.

Work sequence





- Tension toothed belt by turning eccentric to left (direction of arrow) with two hole pin wrench (T10020) onto limit stop.
- Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).
- Tighten securing nut to 20 Nm.
- Turn crankshaft two rotations in engine direction of rotation and set again to DTC No. 1 cylinder. When doing this it is important that last 45° (1/8 turn) is completed without interruptions.
- Check tension of toothed belt again.
Specification: Indicator and notch align

Continued for completing installation of toothed belt
- Install center and lower toothed belt guard
- Install vibration damper/belt pulley.
Tightening torque: 25 Nm
- Install engine mounting to cylinder block.
Tightening torque: 45 Nm
- Install engine assembly mounting complete.

Note: Insert bolts into engine bracket before installing bracket.

- Align assembly mountings for engine and transmission.
- Assembly mounting torque settings.
- Remove engine support device 10-222 A.
- Install toothed belt guard upper part.
- Install poly V-belt tensioning element.
Tightening torque: 25 Nm
- Install poly V-belt.
- Install coolant expansion tank.
- Install power steering reservoir.
- Install right side sound insulation.
- Check engine oil level and top up, if necessary.
- Install engine cover.





Engine code BBW
(Adjusting valve timing)

Special tools and equipment
^ 10-222A Engine support bracket with legs 10-222A/1
^ 2065 A Adjustment bar
^ V.A.G 1331 Torque wrench (5 to 50 Nm)
^ V.A.G 1332 Torque wrench (40 to 200 Nm)
^ T10004 Two hole pin wrench
^ T10172 Counterhold tool

Special tools and equipment





^ T10172/3 Pin

Note: If the toothed belt is to be taken off the camshaft sprocket, e.g. when removing the camshaft or the cylinder head, the following must be considered:

^ Engine bracket, tensioning element for ribbed belt, vibration damper/belt pulley and toothed belt guard (except for upper part) can remain installed.
^ To remove the toothed belt from the camshaft sprocket, unscrew the tensioning roller and slide up to the engine bracket.

Counterhold tool T10172





- Unscrew pins T10172/1.
- Screw pins T10172/3 in and tighten.

Removing
- Remove engine cover.
- Remove right side sound insulation.
- Remove poly V-belt.
- Remove tensioning element for poly V-belt.
- Remove intake manifold upper part.
- Remove toothed belt guard upper part.
- Remove coolant expansion tank (supply hose remains connected, close union for return supply hose).
- Remove power steering reservoir (hoses remain connected).
- Disconnect connector of camshaft timing adjustment valve.
- Remove cylinder head cover.





- Mount support 10-222A with legs 10-222A/1 as shown.





- Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body, and assembly mounting bracket/body (arrows) and remove assembly mounting complete.

Note:
^ Only remove the engine mounting when the engine is secured with the support bracket 10-222A.
^ The engine bracket must be only released when the engine mounting is removed.





- Remove vibration damper/belt pulley.





- Remove engine bracket from cylinder block.

Note: When loosening the front engine mounting bolt the engine must be raised slightly with the support device.

- Remove toothed belt guard center and lower parts.
- Mark direction of rotation of toothed belt.
- Turn crankshaft until camshaft is set to TDC No. 1 cylinder.





Adjustment bar 2065 A must be pushed into slot of camshaft.
- Remove tool.
- Release tensioner and take off toothed belt.
- Turn crankshaft against engine direction of rotation 45°.

Installing

Requirements
^ Pistons must not be positioned at TDC.
^ Engine must only be hand touch warm.

Tensioning toothed belt and adjusting valve timing

Note:
^ When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
^ Never use the adjustment bar 2065 A as counter-hold when loosening and tightening the camshaft sprocket! Use counterhold tool T10172 with pin T10172/3.





- Place a flat container under camshaft sprocket to collect oil leaking out when sealing
plug -1- is loosened.
- Unscrew sealing plug -1- carefully and collect leaking oil. Do not rotate crankshaft, if possible.

Note: To loosen the sealing plug use counterhold tool T10172 with pin T101 72/3, if necessary.

- Clean oil from camshaft sprocket with a cloth.
- Remove camshaft pulley bolt. Do not rotate crankshaft, if possible.





- Use counterhold tool T10172 with pin T10172/3 to loosen camshaft bolt.
- Take camshaft sprocket off camshaft and clean it.

Note:
^ The teeth of the camshaft sprocket and the running surface of the camshaft must be free of oil.
^ In this condition, replacement of the camshaft seal is recommended as a preventative and inexpensive measure.

- Install camshaft sprocket again and camshaft bolt.





- Set camshaft to TDC No. 1. Cyl. and insert adjustment bar 2065 A.
- Loosen camshaft bolt until camshaft sprocket can be turned by hand. Use counterhold tool T10172 with pin T10172/3.
- Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation).
- Install toothed belt guard center and lower parts and belt pulley/vibration damper.





- Turn crankshaft in engine direction of rotation again at TDC No. 1 Cyl.
Notch -2- on belt pulley/vibration damper must align with notch -1- on toothed belt guard, upper part.
- Turn camshaft sprocket so that counterhold tool T10172 with pin T10172/3 can be inserted.
- Place toothed belt on tensioning roller and camshaft sprocket.





- Turn tensioning roller on eccentric with two hole pin wrench (T10004) five times onto limit stop in both directions.
- Tension toothed belt by turning eccentric to left (direction of arrow) with two hole pin wrench (T10004) onto limit stop.
- Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).
- Tighten securing nut to 20 Nm.
- Check TDC of crankshaft again, correct if necessary.

Note: If the crankshaft is positioned after TDC No. 1 cylinder turn the crankshaft again a bit against the engine direction of rotation and set to TDC No. 1 cylinder.





- Hold crankshaft sprocket with counterhold T10172 (pin T10172/3) and tighten camshaft bolt to 40 Nm.
- Remove setting bar 2065 A.
- Counter-hold camshaft sprocket and tighten camshaft bolt to 130 Nm.





- Turn crankshaft two rotations in engine direction of rotation until setting bar 2065 A can be inserted.

Note:
^ It is essential that the last 45° (1/8 turn) is performed without stopping.
^ If the crankshaft has been turned to far, turn the crankshaft 1/4 turn back and set the camshaft to TDC No. 1 cylinder again (insert the setting bar 2065 A).





- Check TDC of crankshaft.
Notch -2- on vibration damper/belt pulley must be positioned -a- (max. 5 mm) after TDC marking -1- on toothed belt guard lower part.
If the crankshaft is not in this area:
- Repeat adjustment.
If the crankshaft is in this area:





- Check toothed belt tension again and adjust if necessary.
Specification: Indicator and notch align

Continuation, completing installation of toothed belt





- Install sealing plug -1- (replace O-ring).
Tightening torque: 25 Nm
- Install engine mounting to cylinder block.
Tightening torque: 45 Nm

Note:
^ - Insert bolts into engine bracket before installing engine bracket.
^ Tighten all bolts of the engine bracket, with the tightening torque mentioned, before installing the engine mounting.

- Install engine assembly mountings complete.
- Align assembly mountings for engine and transmission.
- Remove engine support device 10-222 A.
- Install toothed belt guard upper part.
- Install poly V-belt tensioning element.
Tightening torque: 25 Nm
- Install poly V-belt.
- Install coolant expansion tank.
- Install power steering reservoir.
- Install cylinder head cover.
- Connect connector of camshaft timing adjustment valve.
- Install intake manifold upper part.
- Start engine and run briefly at idling speed (oil pressure increase in camshaft adjustment).
- Install right side sound insulation.
- Check engine oil level and top off, if necessary.
- Install engine cover.
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