Timing Belt: Service and Repair

Toothed Belt

Special tools, testers and auxiliary items required

• Engine Support Bracket (T10339)

• Adapter (10-222 A/18)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Engine Support Bridge (10-222 A)

• Engine Support Feet (10-222 A/8)

Removing

- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover With Air Filter.


• The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

• For safety reasons, remove the fuel pump control module (J538) fuse from the fuse panel before opening the fuel system. This prevents the fuel pump from being activated by the drivers door contact switch.

- Disconnect the vent line - 1 - and the fuel supply line - 2 -.






- Disconnect the vent line - 2 - and remove the Evaporative Emission (EVAP) canister - A - with the hoses upward out of the mount.







Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and carefully open the cap.

- Open and close the coolant expansion tank cap to reduce the pressure.

- Loosen the clamps - arrow - and disconnect the coolant hose. Collect any leaking coolant with a cloth.






- Disconnect the connector - 1 -, remove the bolts - arrows - and set the coolant expansion tank aside.






- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.

- Remove the ribbed belt tensioner - A - and install the engine support bracket (T10339) to both of the upper threaded holes.






- Cover both of the engine support feet (10-222 A/8) in the lower area with electrical tape - arrow -.






- Install the engine support bridge (10-222 A) with the engine support feet (10-222 A/8) and the adapter (10-222 A/18) onto the longitudinal member.






• Install the engine support feet (10-222 A/8) next to the bolt - arrow 2 - just before the raised section - arrow 1 -.

- Remove the bolts - arrows - and remove the toothed belt guard.






- Remove the noise insulation.

- Remove the left front section wheel housing liner and the right front wheel housing liner.

- Remove the bolts - arrows - and remove the charge air pipe and hose.






- Set the camshaft sprocket to the mark for Top Dead Center (TDC) by turning the crankshaft. The mark on the camshaft sprocket must align with the arrow on the toothed belt guard.






- Remove the vibration damper bolts and damper.






• The TDC marks must align before removing the vibration damper.

• The crankshaft must not be rotated any more until the TDC position is marked with an assisting mark.

- Remove the lower toothed belt guard - arrows - bolts.






- Mark the TDC position - arrow -.






- Remove the engine mount bracket bolt - 3 -.






• The next step is necessary in order to be able to raise the engine far enough.

- Remove the pendulum support bolts - 2 and 3 -.






- Remove the engine mount to engine mount bracket bolts - arrows - and remove the mount completely.







Make sure that no components/hoses are damaged, overstretched or torn when lifting the engine using engine support bridge (10-222 A).

- Loosen the upper engine mount bracket bolts - 1 and 2 - and remove them, while lifting the engine using the engine support bridge (10-222 A).






- Remove both of the upper toothed belt guard bolts - arrows - and remove the toothed belt guard downward from the engine.






- Remove the engine mount bracket upward from the engine.

- Mark the rotation direction of the toothed belt.

- Loosen the belt tensioner and remove the toothed belt.

- Turn the crankshaft slightly backward.

Installing

• The crankshaft may not be at TDC by turning the camshaft (there is a risk of damaging the vents/piston crowns).

• The engine must be no more than warm to touch.

- Position the camshaft and crankshaft onto the TDC marks.






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

- Install the toothed belt in the following sequence; belt tensioner, camshaft sprocket, coolant pump and lastly the idler roller - arrow -.






• Be sure the belt tensioner is properly seated in the cylinder head - arrow -.






- Using a hex wrench, turn the tensioner toward the right in the - direction of the arrow - to tension the toothed belt until the notch is above the tab (toothed belt is over tensioned).






- Relieve the tension on the toothed belt again.

- Tension the toothed belt until the notch is across from the tab.

- Tighten the tensioner nut to 25 Nm.

- Rotate the crankshaft 2 additional revolutions in engine rotation direction until the engine is again at TDC. For this it is necessary that the last 45° (1/8) rotation is turned without interruption.

- Check the toothed belt tension. Specified value: Tab and notch align.

- Check the valve timing. The marks must correspond - arrows -.






If the marks do not match:

- Repeat the adjustment for the valve timing.

If the marks match:

- Position the engine mount bracket to the engine.

- Install the lower toothed belt guard bolts - arrows -.






- Install the vibration damper with new bolts. Tightening specification: 10 Nm + an additional 90° (1/4) turn.

- Check the valve timing. The marks must correspond - arrows -.






- Tighten the both of the upper toothed belt guard bolts - arrows -.






- Secure the engine mount bracket to the cylinder block and tighten the bolts hand tight.

• Note the different lengths of the bolts. Bolt - 3 - is approximately 25 mm shorter than bolts - 1 and 2 -.






- Lower the engine using the engine support bridge (10-222 A) to tighten the lower bolt - 3 -.

- Tighten all the bolts to 45 Nm.

- Install the engine mount. Tightening specification, refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.

- Bring the contact surfaces together using the engine support bridge (10-222 A) to tighten the bolts - arrows - for the engine mount to engine mount bracket.






- Align the engine mount as follows:

• There must be a distance of at least 10 mm - a - present between the engine mount bracket - 2 - and the right longitudinal member.






• The casting edge on the engine mount bracket - 2 - must be parallel to the engine mount support arm - 1 -.

- Tighten the bolts for the engine mount and engine mount bracket. Tightening specification, refer to=> [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.

- Remove the engine support bridge (10-222 A).

- Remove the engine support bracket (T10339) and install the ribbed belt tensioner.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.

- Reconnect the fuel, and vent lines making sure that the couplings are stable and secure.

- Install the coolant expansion tank.

- Install the noise insulation.

- Place the fuse for the fuel pump control module back into the fuse panel.

- Install the engine cover with air filter.