Volkswagen Cars 2000-05

Timing Belt 2

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Removal & Installation



1.8L (Awp/Aww) 4-Cylinder Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover and splash shield.
  4.  
  5. Remove the right side headlight assembly.
  6.  
  7. Remove the intake pipe between the turbocharger and the charge air cooler.
  8.  
  9. 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 serpentine drive belt and release the tensioner.
  10.  


NOTE
If necessary to lock the alternator tensioner in position, align the housing holes and insert an Allen wrench into the holes to secure its movement.

  1. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  2.  
  3. Remove the upper timing belt cover.
  4.  


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

  1. Use an engine hoist and take the weight off the engine.
  2.  
  3. Remove the engine mount and body mount bolts and remove the engine mount from the cylinder block.
  4.  
  5. Remove the damper pulley-to-crankshaft bolts and the damper.
  6.  
  7. Remove the center and lower timing belt covers.
  8.  
  9. Place tensioning bolt T10092 into the timing belt tensioner and tension the element so the tensioner piston can be locked with a locking pin.
  10.  
  11. Remove the timing belt.
  12.  
  13. turn the crankshaft back slightly so the pistons are not at TDC.
  14.  


    Click image to see an enlarged view

    Fig. Removing engine and bolt mounts bolts-1.8L (AWP/AWW) 4-Cyl engine


To install:

  1. Align the camshaft sprocket timing mark with the cylinder head cover mark.
  2.  
  3. Install the timing belt on the crankshaft sprocket with the arrow facing the rotational direction.
  4.  
  5. Install the engine mount and body mount bolts to the cylinder block and tighten to 33 ft. lbs. (45 Nm).
  6.  
  7. Install the lower timing belt cover and tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Using a bolt, secure the damper/belt pulley on the crankshaft.
  10.  
  11. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  12.  
  13. Install the timing belt on the camshaft sprocket, water pump and belt tensioner.
  14.  
  15. Remove locking pin and tensioning tool from the belt tensioner.
  16.  
  17. Rotate the crankshaft 2 complete rotation in the running direction.
  18.  
  19. Check that the crankshaft and camshaft timing marks are still aligned.
  20.  
  21. Install the crankshaft pulley bolts and tighten to 18 ft. lbs. (25 Nm).
  22.  
  23. Install the center timing belt cover and tighten the bolts to 89 inch lbs. (10 Nm).
  24.  
  25. Install the upper timing belt cover.
  26.  
  27. Install the drive belts.
  28.  
  29. Replace the remaining components by reversing the removal procedures.
  30.  
  31. Install the negative battery cable last.
  32.  
  33. Test drive the vehicle.
  34.  

1.9L Diesel Engine

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.

    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

  10.  

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

  8.  

2.0L (9a, Aba) Engines
  1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s).
  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 distributor cap removed, the rotor should be pointing toward the No. 1 mark on the rim of the distributor housing. On 8 valve engines, the notch on the crankshaft pulley should align with the dot on the intermediate shaft sprocket.
  6.  
  7. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt.
  8.  
  9. Slide the timing belt from the sprockets.
  10.  



Click image to see an enlarged view

Fig. Adjusting the belt tension on a 2.0L 8 valve



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Fig. Remove the timing belt cover



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Fig. Align the timing marks



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Fig. Locate the tensioner



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Fig. Loosen the tensioner bolt



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Fig. Mark the belts direction of rotation

To install:

  1. Check the alignment of the timing marks. On 16-valve engines, the mark on the tooth should align with the mark on the rear belt cover.
  2.  
  3. Install the new timing belt and tension the belt so it can be twisted 90° at the middle of it's longest section, between the camshaft and intermediate sprockets.
  4.  
  5. Recheck the alignment of the timing marks and, if correct, turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck belt tension and timing marks. Readjust as required. Torque the tensioner nut to 33 ft. lbs. (45 Nm).
  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.  

2.0L (AEG) 4-Cylinder Engine
  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 an open-end wrench, rotate the serpentine drive belt tensioner clockwise to relieve the belt tension. Using tool 3090 or a drift awl, lock the tensioner in place.
    2.  
    3. Remove the serpentine drive belt.
    4.  

  6.  
  7. Remove the drive tensioner from the engine.
  8.  
  9. Rotate the crankshaft to position the No. 1 cylinder on Top Dead Center (TDC) of its compression stroke.
  10.  
  11. Remove the upper timing belt cover.
    NOTE
    If the camshaft sprocket is not aligned with its timing mark, rotate the crankshaft 1 complete turn until the crankshaft and camshaft timing marks align.

  12.  
  13. Install the Engine Support tool 10-222A with Leg tools and support the weight of the engine.
  14.  
  15. From the front of the engine, remove the engine mount and bracket which will interfere with the timing belt removal.
  16.  
  17. Mark the rotational direction of the timing belt for reinstallation purposes.
  18.  
  19. Remove the vibration damper-to-crankshaft sprocket bolts and the damper.
  20.  
  21. Remove the center and lower timing belt covers.
  22.  
  23. Release the timing belt tensioner and remove the timing belt.

    Click image to see an enlarged view

    Fig. View of crankshaft damper aligned with the timing mark-Volkswagen 2.0L (AEG) 4-Cyl. engine-Beetle



    Click image to see an enlarged view

    Fig. View of camshaft damper aligned with the timing mark-Volkswagen 2.0L (AEG) 4-Cyl. engine-Beetle



    Click image to see an enlarged view

    Fig. Adjusting the timing belt tensioner-Volkswagen 2.0L (AEG) 4-Cyl. engine-Beetle

  24.  

To install:

  1. Make sure that the camshaft and crankshaft timing marks are aligned.
  2.  
  3. Install the timing belt, with the arrow pointing in the direction of rotation, on the crankshaft sprocket, the water pump sprocket and the camshaft sprocket.
  4.  
  5. Install the lower and center timing belt covers.
  6.  
  7. Install the vibration damper and torque the damper-to-crankshaft sprocket bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Using the 2-Hole Tensioning tool T-10020, rotate the timing belt tensioner counterclockwise until notch 1 and indicator 2 align. Then, tighten the timing belt tensioner nut to 15 ft. lbs. (20 Nm).
  10.  
  11. Rotate the crankshaft 2 complete revolutions and recheck the timing marks.
  12.  
  13. Install the upper timing belt cover.
  14.  
  15. Install the engine bracket and torque the bolts to 33 ft. lbs. (45 Nm).
  16.  
  17. Install the engine mount and torque the mount-to-bracket bolts to 30 ft. lbs. (40 Nm) plus 90 degree turn ( 1 / 4 turn), the mount-to-body bolts to 18 ft. lbs. (25 Nm) and the mount-to-engine bracket bolts to 44 ft. lbs. (60 Nm) plus 90 degree turn ( 1 / 4 turn).
  18.  
  19. Install the timing belt tensioner and torque the bolts to 18 ft. lbs. (25 Nm).
  20.  
  21. Complete the installation by reversing the removal procedures.
  22.  
  23. Test drive the vehicle.
  24.  

2.8L (AHA) 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.
      NOTE
      The viscous fan is mounted with a left-handed thread; turn it clockwise to loosen it.

    2.  
    3. 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.
    4.  
    5. Mark the running direction of the serpentine drive belt and remove it from the pulleys.
    6.  

  6.  
  7. 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.
  8.  
  9. On the left side of the cylinder block near the crankshaft, remove the sealing plug.
  10.  
  11. Insert Crankshaft Holder tool No. 3242 into the sealing plug hole to secure the crankshaft.
  12.  
  13. 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.
  14.  
  15. Remove the dampener-to-crankshaft bolts and the damper.
    NOTE
    It is not necessary to remove the center bolt when removing the crankshaft damper.

  16.  
  17. Remove the serpentine belt idler and the crankshaft damper guard.
  18.  
  19. Mark the running direction of the timing belt and remove it from the pulleys.

    Click image to see an enlarged view

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



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



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



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

  20.  

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° ( 1 / 2 turn).
  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.  

 
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