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Timing Belt: Service and Repair




TOOTHED BELT, REMOVING AND INSTALLING:

Adjusting Valve Timing:

Special Tools, Testers And Auxiliary Items:
^ Ring spanner 3355
^ Counter-hold tool 3248 A
^ Torque wrench VAG 1331 5 to 50 Nm (4 to 40 ft lb)
^ Torque wrench VAG 1601 150 to 800 Nm (100 to 600 ft lb)

Removing:
- Removing sound dampening tray.
- Remove V-bell or ribbed belt. Service and Repair
- Remove front toothed belt guard -upper part-.




- Fit counterhold tool 3419 and loosen vibration damper/crankshaft sprocket.
- Remove vibration damper center bolt.
- Remove the 4 x M8 crankshaft vibration damper/toothed belt pulley mounting bolts.
- Remove vibration damper.
- Remove front toothed belt guard -lower part-.
- Mark direction of rotation of toothed belt.
- Loosen tensioning roller or coolant pump and remove toothed belt.

Installing:

^ Pistons not positioned at TDC

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

Vehicles from 08.95:



- Install tensioning roller -1- so that the tensioning roller tab seats in the toothed belt guard lower section moving pin -arrow A-.
- Tighten tensioning roller mounting bolt hand tight.

Continued for all vehicles:
- Place toothed belt on crankshaft sprocket, relay roller or tensioning roller and coolant pump (note direction of rotation}.

Vehicles up to 07.95:
- Install lower toothed belt guard and fit mounting bolt M8 for coolant pump.
If tensioning roller is installed
- Tighten to 20 Nm (15 ft lb).

Continued for all vehicles:
- Torque vibration damper to crankshaft toothed belt sprocket (4 M8 bolts).
^ V-belt pulley: 20 Nm (15 ft lb)
^ Ribbed belt pulley: 20 Nm (15 ft lb) + 1/4 turn (90° further)
- Install vibration damper central bolt.

Vehicles with long center bolt (110 mm):



- Insert counter-hold tool 3419 and tighten crankshaft vibration damper/crankshaft toothed belt sprocket center bolt.
^ 160 Nm (118 ft lb) plus 180° (1/2 turn additional) the additional 1/2 turn can be completed in several stages.

Vehicles with short central bolt (65 mm):
- Coat threads and bolt head contact surface of central bolt with AMV 188001 02.



- Insert counterhold 3419 and secure vibration damper/crankshaft sprocket.
^ Tightening torque: 460 Nm (340 ft lb).

Continued for all vehicles:



- Set camshaft sprocket to marking TDC Cyl. 1. The marking on the camshaft sprocket must align with the mark on the rear toothed belt guard -arrow-.

Engine installed:



- Set flywheel -A- or drive plate -B- to TDC No.1 cylinder.

Engine removed:
- Bring mark on vibration damper -C- and mark on lower toothed belt guard into alignment.

TENSIONING TOOTHED BELT:

Adjustment Conditions:
^ Engine cold

Vehicles with tensioning roller up to 07.95:



- Loosen nut -1- and check that tensioning roller moves freely, then place toothed belt on camshaft sprocket (note direction of rotation).
- Tighten tensioning roller mounting bolt hand tight.
- Turn engine approx. 2 turns until just before TDC.
- To tension toothed belt, turn crankshaft slowly to TDC position (crankshaft must not jump back) tighten tensioning roller nut.
^ Tightening torque: 15 Nm (11 ft lb).

Vehicles with tensioning roller from O8.95:
- Place toothed belt on crankshaft sprocket. For used belts note direction of rotation.

NOTE: For used belts, note or mark the direction of rotation.

- Tighten tensioning roller mounting bolt hand tight.



- Turn tensioning roller clockwise onto the tensioning roller internal stop using 3355 box wrench . Then turn tensioning roller back until both pointers are aligned -arrow B-.
- Tighten tensioning roller mounting bolt
^ 2O Nm (15 ft lb).

Vehicles without tensioning roller:



- Place toothed belt on camshaft sprocket.
- Tension toothed belt by turning loosened coolant pump to left and upward.

NOTE: On older engines, VW recommends that sealing surfaces be cleaned and the 0-ring replaced when loosening the coolant pump.




It must just be possible to turn the toothed belt through 90° with the thumb and forefinger in the center between camshaft and intermediate shaft sprockets.

- Tighten coolant pump mounting bolts
^ 2O Nm (15 ft lb).

Continued for all vehicles:
- Rotate crankshaft two full turns and check adjustment.
- Install upper toothed belt guard.
- Check ignition timing and adjust if necessary.
- Install ribbed belt. Service and Repair
- Install power steering pump V-belt and adjust.
- Install generator V-belt and adjust.



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