Timing Belt: 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 legs 10-222A/B
3180 Retainer (for turbocharged engines)
T10092 Tensioning bolt
T40011 Locking pin
VAG 1331 Torque wrench (5 to 50 Nm)
VAG 1332 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.
Refer to Body and Frame - Sound Proofing/Insulation - Service and Repair - Procedures Service and Repair






- Remove air duct to charge air cooler at bottom right of long member.
- Remove ribbed belt.
Refer to Drive Belts, Mounts, Brackets and Accessories - Drive Belt - Service and Repair - Procedure Service and Repair

- 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 of 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 mount on cylinder block.






- 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 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.
Refer to B - Toothed belt only taken on camshaft sprocket

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.
For engine mount alignment and tightening torques refer to Drive Belts, Mounts, Brackets and Accessories - Engine Mount 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
Refer to Body and Frame - Sound Proofing/Insulation - Service and Repair - Procedures Service and Repair