Volkswagen Cars 2000-05

Timing Belt, Cover, Sprockets, & Seal 1

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Maintenance Intervals




NOTE
There is no recommended timing belt service interval from the manufacturer. We recommended that the belt be inspected every 30,000 miles and replaced at every 60,000 mile interval. If the belt stretches there is a chance that it may jump a tooth throwing the timing off. If this occurs one or more of the pistons could contact the valves causing extensive damage.

If the vehicle has been stored for long periods (2 years or more), the belt should be changed before returning the vehicle to service.

Removal & Installation





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Fig. Exploded view of the timing cover



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Fig. Remove the timing cover bolts



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Fig. Carefully pull the cover away from the belt



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Fig. View of the timing belt on a 2.0L-cover removed

  1. Remove the accessory drive belts.
  2.  
  3. To remove the crankshaft accessory drive pulley, hold the center crankshaft sprocket bolt with a socket and loosen the pulley bolts.
  4.  
  5. The cover is now accessible. It comes off in 2 pieces, remove the upper half first. Take note of any special spacers or other hardware.
  6.  

To install:

  1. Installation is the reverse of removal.
  2.  


NOTE
Do not turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.

2.8L (Aha/Atq) V6 Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the necessary components to gain access to the front of the engine.
  4.  
  5. Remove the serpentine drive belt by performing the following procedure:
    1. Using Spanner Wrench No. 3212, secure the viscous fan pulley. Using an Open-end Spanner Wrench 3212, remove the viscous fan bearing housing by turning it clockwise.
    2.  

  6.  


NOTE
The viscous fan is mounted with a left-handed thread; turn it clockwise to loosen it.

  1. Place a 17mm box wrench on the serpentine drive belt tensioner and turn the tensioner clockwise until the 2 holes align; insert drift 3204 into the holes to secure the tensioner in place.
  2.  
  3. Mark the running direction of the serpentine drive belt and remove it from the pulleys.
  4.  

  1. Rotate the crankshaft by hand to align the crankshaft pulley mark with the arrow on the engine housing and the large hole in each camshaft sprocket must face inward and must align; this should be Top Dead Center (TDC) of the No. 1 cylinder-s compression stroke. If these conditions are not correct, rotate the crankshaft one complete revolution and realign.
  2.  
  3. On the left side of the cylinder block near the crankshaft, remove the sealing plug.
  4.  
  5. Insert Crankshaft Holder tool No. 3242 into the sealing plug hole to secure the crankshaft.
  6.  
  7. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, insert a 2mm spring pin through the tensioner housing and tensioner plunger to secure it in place. When the plunger is secure, release the wrench tension.
  8.  
  9. Remove the dampener-to-crankshaft bolts and the damper.
  10.  


NOTE
It is not necessary to remove the center bolt when removing the crankshaft damper.

  1. Remove the serpentine belt idler and the crankshaft damper guard.
  2.  
  3. Mark the running direction of the timing belt and remove it from the pulleys.
  4.  


    Click image to see an enlarged view

    Fig. Crankshaft pulley alignment location for TDC-Volkswagen 2.8L (AHA/ATQ) V6 engine



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    Fig. Left camshaft sprocket alignment position for TDC; right camshaft position is similar-Volkswagen 2.8L (AHA/ATQ) V6 engine



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    Fig. View of crankshaft holding tool installed-Volkswagen 2.8L (AHA/ATQ) V6 engine



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    Fig. View of camshaft locator bar installed-Volkswagen 2.8L (AHA/ATQ) V6 engine


To install:

  1. Make sure that the camshaft pulleys and the crankshaft pulley are in alignment with TDC of the No. 1 cylinder-s compression stroke.
  2.  
  3. Install the timing belt; make sure the timing belt is installed in the correct running direction from which it was removed.
  4.  
  5. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, remove the 2mm spring pin from the tensioner housing. Slowly, release the tensioner-s spring pressure to put pressure on the timing belt.
  6.  
  7. Install the crankshaft damper guard and the serpentine belt idler pulley; torque the idler pulley bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the crankshaft damper and torque the damper-to-crankshaft bolts to 15 ft. lbs. If the damper-to-crankshaft center bolt was removed, torque it to 147 ft. lbs. (200 Nm) plus 180° (12
  10.  
  11. Remove the Crankshaft Holder tool No. 3242 and install the sealing plug.
  12.  
  13. Replace the remaining components by reversing the removal procedures.
  14.  
  15. Refill the cooling system and the automatic transaxle. Connect the electrical connectors. Install the negative battery cable last.
  16.  
  17. Test drive the vehicle.
  18.  

2.8L (Bdf) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove engine covers at the front of the engine compartment and underneath the vehicle.
  6.  
  7. Mark the rotation direction of the drive belt.
  8.  
  9. Insert an M8x50 bolt into the threaded hole of the belt tensioner roller and tighten just enough until tension is off belt and drive belt can be removed.
  10.  
  11. Remove the cylinder head cover.
  12.  
  13. Remove the necessary components to gain access to the front of the engine.
  14.  
  15. Place the crankshaft at TDC for no. 1 cylinder.
  16.  
  17. Mark the camshaft timing chain rotation direction with a paint mark.
  18.  
  19. Remove the camshaft roller chain tensioner.
  20.  
  21. Remove the 8 mounting bolts and remove the chain front cover
  22.  
  23. Disconnect the front exhaust pipe from the exhaust manifold.
  24.  
  25. Check that timing is at TDC by looking down between timing chain sprockets of the intermediate shaft. A groove should be visible between the chain edges.
  26.  


NOTE
If the groove cannot be seen, turn crankshaft one more revolution until groove can be seen.

  1. Insert camshaft gauge T10068 into both camshaft grooves.
  2.  


NOTE
If the gauge cannot be inserted, rotate crankshaft about .20 inches (5 mm) above TDC position until gauge can be inserted.


NOTE
Markings -A- and -B- on the camshaft adjusters must match the notches of control housing -C.-

  1. Remove the camshaft adjusters together with the timing chain from the camshafts.
  2.  
  3. Remove the two bolts from the glide track located at lower left below camshaft sprocket.
  4.  
  5. Remove the timing chain from the camshaft adjusters and place chain on its side.
  6.  


    Click image to see an enlarged view

    Fig. Lining up camshaft adjusters to remove timing chain-2.8L (BDF) engine



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    Fig. Identifying TDC position on timing chain sprockets of intermediate shaft-2.8L (BDF) engine



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    Fig. Identifying timing chain positioning on crankshaft and intermediate shaft sprockets-2.8L (BDF) engine


To install:

  1. Adjust the milled tooth of the drive pinion to line up with the bearing separating gap at TDC on cylinder no. 1.
  2.  
  3. Install the glide track bolts, without the collar, and torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the timing chains and the intermediate shaft gears (if removed), ensuring that the timing chain rotation direction is correct.
  6.  
  7. Check that the marking on the gear matches with the notches on the intermediate shaft thrust washer.
  8.  
  9. Hand tighten the intermediate shaft gear bolts.
  10.  
  11. Use a small screwdriver to release the tension of the locking splines in the chain tensioner and press the tensioner track against the tensioner.
  12.  
  13. Install the timing chain tensioner bolts and torque to 72 inch lbs. (8 Nm).
  14.  
  15. Use a socket wrench to hold the crankshaft damper in position.
  16.  
  17. With the intermediate shaft sprockets lined up correctly, torque the bolts to 44 ft. lbs. (60 Nm), plus 90°.
  18.  
  19. Check that all sprockets are correctly lined up and cylinder no. 1 is at TDC.
  20.  
  21. Insert camshaft adjusting ruler tool T10068 into camshaft grooves.
  22.  
  23. Guide the timing chain between the tensioning track and the glide track.
  24.  
  25. Install the intake camshaft adjuster first with the timing chain installed, then install the exhaust camshaft adjuster.
  26.  


NOTE
Exhaust camshaft adjuster can be offset in two directions. When installing, make sure the camshaft position sensor is turned to stop in a clockwise direction. Distance between the milled teeth markings on the timing chain at the camshaft adjuster markings is exactly 16 rollers on the timing chain.


NOTE
Markings -A- and -B- on the camshaft adjusters must match the notches of control housing -C.-

  1. Hand tighten NEW bolts for camshaft adjusters.
  2.  
  3. Remove camshaft adjusting ruler T10068.
  4.  
  5. Rotate crankshaft 2 revolutions and recheck valve timing.
  6.  
  7. If valve timing is okay, secure camshafts in position and torque camshaft adjuster bolts to 44 ft. lbs. (60 Nm), plus 90°.
  8.  
  9. Place oil on the front cover O ring and install in cover.
  10.  
  11. Coat the front cover sealing surface with sealant and hand tighten the bolts.
  12.  
  13. Torque the front cover M6 bolts to 72 inch lbs. (8 Nm), and tighten the M8 bolts to 18 ft. lbs. (25 Nm).
  14.  
  15. Install the camshaft roller chain tensioner and torque the bolts to 30 ft. lbs. (40 Nm).
  16.  
  17. Rotate crankshaft 2 revolutions and recheck valve timing.
  18.  
  19. Replace the remaining components by reversing the removal procedures.
  20.  
  21. Reconnect the negative battery cable.
  22.  
  23. Test drive the vehicle.
  24.  

4.0L (Bdp) Engines

NOTE
The following procedure is for cylinder bank no. 1. Cylinder bank no. 2 is similar.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove or disconnect:

    Upper intake manifold.
     

  14.  
  15. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  16.  
  17. Remove the ignition coils using T10094 extractor.
  18.  
  19. Remove or disconnect:

    Cylinder head cover
     
    Fuel rail with injectors.
     
    Lower intake manifold spacer.
     

  20.  


NOTE
Cover intake ports to prevent debris from entering.



Coolant pipes.
 
Intake pipes.
 

  1. Turn the crankshaft until no. 1 cylinder is at TDC. Mark on crankshaft damper must align with mark on cylinder block joint.
  2.  
  3. Remove the camshaft chain tensioner.
  4.  
  5. Remove the timing chain upper cover.
  6.  
  7. Remove the timing chain lower cover.
  8.  
  9. Mark the timing chain rotation direction for installation.
  10.  
  11. Remove the exhaust camshaft adjuster bolts.
  12.  
  13. Remove the intake camshaft adjuster bolts.
  14.  
  15. Remove the camshaft adjusters together with the timing chain.
  16.  
  17. Remove the timing chain guide rail.
  18.  


    Click image to see an enlarged view

    Fig. Locating TDC alignment marks-4.0L engine


To install:

  1. Set the crankshaft and camshafts to TDC for cylinder No. 1.
  2.  
  3. Secure the crankshaft from turning.
  4.  
  5. Install camshaft adjuster guide T10068 into horizontal slots on camshafts to lock them in place
  6.  
  7. On cylinder bank no. 1, install the timing chain as follows:
  8.  
  9. On the intake camshaft adjuster, turn the Hall sensor wheel clockwise to its stop.
  10.  
  11. On the exhaust camshaft adjuster, turn the Hall sensor wheel counterclockwise to its stop.
  12.  
  13. Install the timing chain and camshaft adjuster as a unit.
  14.  
  15. Copper link -A- of timing chain must be positioned on the top of the intermediate shaft.
  16.  
  17. Copper link of timing chain must align with -B1- arrow on intake camshaft adjuster
  18.  
  19. Copper link of timing chain must align with -B1- arrow on exhaust camshaft adjuster
  20.  
  21. Tighten NEW camshaft adjuster bolts hand tight.
  22.  
  23. Install the guide rail and tensioning rail.
  24.  
  25. On cylinder bank no. 2, install the timing chain as follows:
  26.  
  27. On the intake camshaft adjuster, turn the Hall sensor wheel clockwise to its stop.
  28.  
  29. On the exhaust camshaft adjuster, turn the Hall sensor wheel counterclockwise to its stop.
  30.  
  31. Install the timing chain and camshaft adjusters as a unit.
  32.  
  33. Copper link -A- of timing chain must be positioned on the top of the intermediate shaft.
  34.  
  35. Copper link of timing chain must align with -B2- arrow on intake camshaft adjuster
  36.  
  37. Copper link of timing chain must align with -B2- arrow on exhaust camshaft adjuster
  38.  
  39. Tighten NEW camshaft adjuster bolts hand tight.
  40.  
  41. Install the guide rail and tensioning rail.
  42.  
  43. Install the chain tensioner limit stop and tighten to 15 ft. lbs. (20 Nm).
  44.  
  45. Install the chain tensioner and tighten to 71 inch lbs. (10 Nm).
  46.  
  47. On both cylinder banks, proceed as follows:
  48.  
  49. Remove camshaft adjuster guide T10068 from both heads.
  50.  
  51. Hold crankshaft from turning and install NEW intermediate sprocket bolt and tighten to 44 ft. lbs. (60 Nm).
  52.  
  53. Hold camshafts in place with a 32 mm open end wrench, and tighten NEW camshaft adjuster bolts to 44 ft. lbs. (60 Nm).
  54.  
  55. Install lower timing chain cover and tighten bolts in sequence.
  56.  
  57. Install sealant to cylinder bank no. 1 upper timing belt cover and tighten bolts in sequence to 71 inch lbs. (10 Nm).
  58.  
  59. Install sealant to cylinder bank no. 2 upper timing belt cover and tighten bolts in sequence to 71 inch lbs. (10 Nm).
  60.  
  61. Replace the remaining components by reversing the removal procedures.
  62.  
  63. Reconnect the negative battery cable.
  64.  
  65. Test drive the vehicle.
  66.  


    Click image to see an enlarged view

    Fig. Installing timing chain on cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on intake camshaft adjuster for cylinder bank no. 1-4.0L engine



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    Fig. Locating copper timing chain link with arrow on exhaust camshaft adjuster for cylinder bank no. 1-4.0L engine



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    Fig. Installing timing chain on cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on intake camshaft adjuster for cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on exhaust camshaft adjuster for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for upper timing chain cover for cylinder bank no. 1-4.0L engine



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    Fig. Tightening sequence for upper timing chain cover for cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for lower timing chain cover-4.0L engine


Alh Engines

Some special tools are required to perform this procedure properly. A camshaft locking bar, VW tool 3418 is used to secure the camshaft in position. A pin, VW tool 3359 is used to fix the injection pump position while the timing belt is removed. Camshaft sprocket holding tool 3036 is used to lock the camshaft sprocket. Puller T40001 is needed to remove the camshaft sprocket.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover and splash shield.
  4.  
  5. Place an open-end wrench on the alternator belt tensioner and rotate it clockwise toward the alternator to release the belt-s tension. Remove the alternator drive belt and release the tensioner.
  6.  
  7. Remove the brake booster vacuum pump.
  8.  
  9. Remove the upper timing belt cover.
  10.  
  11. Remove the valve cover.
  12.  
  13. Remove the tube between the intake pipe and the charge air cooler.
  14.  
  15. Rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  16.  


NOTE
If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  1. Install camshaft locking bar onto the camshaft and cylinder head so it is equally balanced between both legs of the tool.
  2.  
  3. Lock the injection pump in place using pin 3359.
  4.  
  5. Loosen the injection pump sprocket bolts in a diagonal sequence.
  6.  


NOTE
DO NOT loosen the pump sprocket hub bolt or the injection pump basic setting will be altered and cannot be reset with normal shop equipment.

  1. Use an engine hoist and take the weight off the engine.
  2.  
  3. Remove the coolant reservoir tank and the power steering fluid reservoir and wire aside without disconnect the fluid lines.
  4.  
  5. Remove the engine mount and body mount bolts on the right side and remove the engine mount from the cylinder block.
  6.  
  7. Remove the left side engine mount bracket.
  8.  
  9. Remove the damper pulley-to-crankshaft bolts and the damper.
  10.  
  11. Remove the center and lower timing belt covers.
  12.  
  13. Release the tension on the belt tensioner and remove the timing belt.
  14.  
  15. Hold the camshaft sprocket with tool 3036 and loosen the camshaft sprocket bolt one turn.
  16.  
  17. Remove the camshaft sprocket using 2-jaw puller T40001.
  18.  

To install:

  1. Install the timing belt onto the crankshaft sprocket, idler pulley, injection pump sprocket, water pump and tensioner.
  2.  
  3. Adjust the injection pump sprocket so the mounting slots are centered.
  4.  
  5. Install the timing belt on the camshaft sprocket, then install the sprocket using the mounting bolt. The camshaft sprocket should still turn.
  6.  
  7. On manual transmission models, tension the timing belt using tool T10020 on the tensioner roller eccentric and turn it clockwise until the notch and the raised mark are aligned as shown.
  8.  
  9. On automatic transmission models, tension the timing belt using an Allen wrench on the tensioner roller eccentric and turn it clockwise until the notch and the pointer are aligned as shown.
  10.  
  11. Using new bolts, tighten the injection pump sprocket bolts to 15 ft. lbs. (20 Nm).
  12.  


    Click image to see an enlarged view

    Fig. Aligning the timing belt tensioner marks on manual transmission models-1.9L (ALH) Diesel engines



    Click image to see an enlarged view

    Fig. Aligning the timing belt tensioner marks on automatic transmission models-1.9L (ALH) Diesel engines



NOTE
After dynamically testing the start of injection, retighten the sprocket bolts an additional 90°.

  1. Remove the camshaft locking tool and the injection pump sprocket locking pin. holding tools.
  2.  
  3. Turn the engine 2 full revolutions to return to TDC for the No. 1 cylinder. Recheck belt tension and timing mark alignment, readjust as required.
  4.  
  5. Install the left side engine mount bracket and tighten the bolts to 33 ft. lbs. (45 Nm).
  6.  
  7. Install the center and lower timing belt covers.
  8.  
  9. Install the crankshaft damper and tighten the bolts to 89 inch lbs. (10 Nm), plus an additional 90°.
  10.  
  11. Install the engine mount and body mount bolts to the cylinder block and tighten to 33 ft. lbs. (45 Nm).
  12.  
  13. The remainder of the installation is the reverse of the removal procedure.
  14.  

Diesel Engines

Some special tools are required. A flat bar, VW tool no. 2065A, is used to secure the camshaft in position. A pin, VW tool no. 2064, is used to fix the pump position while the timing belt is removed. The camshaft and pump work against spring pressure and will move out of position when the timing belt is removed. It is not difficult to find substitutes but do not remove the timing belt without these tools.


NOTE
Do not turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.

  1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s). Remove the camshaft cover and rubber plug at the back end of the camshaft.
  2.  
  3. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to TDC of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner timing belt cover or the edge of the cylinder head.
  4.  
  5. With the engine at TDC, insert the bar into the slot at the back of the camshaft. The bar rests on the cylinder head to will hold the camshaft in position.
  6.  
  7. Insert the pin into the injection pump drive sprocket to hold the pump in position.
  8.  
  9. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt. Slide the timing belt from the sprockets.
  10.  

To install:

  1. Install the new timing belt and adjust the tension so the belt can be twisted 45 degrees at a point between the camshaft and pump sprockets. Torque the tensioner nut to 33 ft. (45 Nm).
  2.  
  3. Remove the holding tools.
  4.  
  5. Turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck belt tension and timing mark alignment, readjust as required.
  6.  
  7. Install the belt cover and accessory drive belts.
  8.  
  9. If the belt is too tight, there will be a growling noise that rises and falls with engine speed.
  10.  

Except Alh Engines

Some special tools are required to perform this procedure properly. A flat bar, VW tool 2065A is used to secure the camshaft in position. A pin, VW tool 2064 is used to fix the pump position while the timing belt is removed. The camshaft and pump work against spring pressure and will move out of position when the timing belt is removed. It is not difficult to find substitutes but do not remove the timing belt without these tools.


WARNING
Do not turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.

  1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s). Remove the camshaft cover and rubber plug at the back end of the camshaft.
  2.  
  3. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner timing belt cover or the edge of the cylinder head.
  4.  
  5. With the engine at TDC, insert the bar into the slot at the back of the camshaft. The bar rests on the cylinder head to will hold the camshaft in position.
  6.  
  7. Insert the pin into the injection pump drive sprocket to hold the pump in position.
  8.  
  9. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt. Slide the timing belt from the sprockets.
  10.  


    Click image to see an enlarged view

    Fig. Use the VW tool to lock the camshaft at TDC for timing belt replacement-Volkswagen 1.9L Diesel engines



    Click image to see an enlarged view

    Fig. Locking the injection pump with the VW tool as shown-Volkswagen 1.9L Diesel engines


To install:

  1. Install the new timing belt and adjust the tension so the belt can be twisted 45 degrees at the halfway point between the camshaft and pump sprockets. Tighten the tensioner nut to 33 ft. lbs. (45 Nm).
  2.  
  3. Remove the holding tools.
  4.  
  5. Turn the engine 2 full revolutions to return to TDC for the No. 1 cylinder. Recheck belt tension and timing mark alignment, readjust as required.
  6.  
  7. Install the belt cover and accessory drive belts.
  8.  


NOTE
If the belt is too tight, there will be a growling noise that rises and falls with engine speed.

 
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