1.2 TDI CR engine (EA189) · Cylinder head, valve gear · Toothed belt drive

Removing, installing and tensioning toothed belts

Special tools and workshop equipment required

  • 2x diesel injection pump locking pin - 3359-
  • Crankshaft stop - T10050-
  • Counter-hold tool - T10172-
  • Angled screwdriver - T10264-
  • Locking tool - T10265-
  • Socket XZN 10 - T10385-

Not illustrated:

  • Torque wrench - V.A.G 1331-
  • Torque wrench - V.A.G 1332-

2.2.1 Removing

»Carry out the following work sequence«

  • Remove upper timing belt guard by detaching clips -arrows-.
  • Remove front right wheel housing liner.
  • Unscrew bolts -arrows-.
  • Remove lower toothed belt guard.
  • Turn engine to TDC and lock crankshaft pulley in position with crankshaft stop - T10050-. Fit the crankshaft stop in the teeth from the face side of the toothed belt pulley.
  • The mark -2- on the toothed pulley and the arrow -1- on the crankshaft stop - T10050- must align -arrow-. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.

The arrow on the camshaft pulley must be at almost »12 o'clock«.

  • Mark direction of rotation of toothed belt.
  • Loosen bolts -arrows- approx. 90° for camshaft toothed belt pulley.
  • Loosen bolts -1- approx. 90° for high-pressure pump toothed belt pulley using bit XZN 10 - T10385-.
  • Loosen securing nut of tensioning roller -1- and turn tensioning roller eccentric using socket - T10264- counter-clockwise -arrow- until tensioning roller can be locked with locking pin - T10265-.
  • Turn eccentric of tensioning roller clockwise -arrow- to stop. Tighten securing nut -1- hand-tight.
  • Remove toothed belt first from idler pulley and then from remaining toothed belt pulleys.

2.2.2 Installing (adjusting valve timing)

  • Tensioning roller must be locked with locking tool - T10265- and secured to right stop.
  • Crankshaft is locked using crankshaft stop - T10050-.
  • Lock the camshaft hub with locking pin - 3359-. To do this, insert locking pin through outer free elongated hole into hole in cylinder head.
  • Loosen the hand-tightened bolt again.

Bolts -arrows- screwed in loosely.

It should just be possible to turn camshaft toothed belt pulley without axial movement.

Positioning hub of high-pressure pump

  • Lock the camshaft hub with locking pin - 3359-. To do this, push locking pin into adjustment hole outside toothed belt pulley.

Loosely tightened bolts -1-.

It should just be possible to turn high-pressure pump toothed belt pulley without axial movement.

  • Turn camshaft sprocket and toothed belt sprocket of highpressure pump in their elongated holes clockwise to stop.
  • Fit toothed belt in sequence described:
  • 1 Crankshaft pulley
  • 2 Tensioning pulley
  • 3 Camshaft toothed belt pulley
  • 4 Coolant pump toothed belt pulley
  • 5 High-pressure pump toothed belt pulley
  • 6 Idler roller
  • Loosen belt tensioner securing nuts and pull out locking tool - T10265-.
  • Carefully turn eccentric of tensioning roller clockwise using angle driver - T10264-. Indicator -2- must be roughly past the centre of the gap in the base plate (corrects itself during pretensioning).

Ensure that securing nut -1- does not turn as well.

  • Hold tensioning roller in this position. Tighten tensioning roller securing nuts as follows: 20 Nm and turn 45° further.
  • Fit counterhold - T10172- as shown. Press counterhold - T10172- in direction of arrow and keep camshaft sprocket in pretensioning position.
  • In this position, first tighten securing bolts -1- of camshaft pulley and of toothed belt pulley for high-pressure pump by hand, and then tighten them to 20 Nm.
  • Remove locking pins - 3359- and crankshaft stop - T10050-.
  • Turn crankshaft at least two rotations in engine direction of rotation and set to just before TDC No. 1 cylinder.
  • Place crankshaft stop - T10050- on the crankshaft's toothed belt pulley again.
  • Now turn crankshaft in engine direction of rotation until crankshaft stop pin -arrow- engages in sealing flange whilst turning.
  • Check whether:
  • Camshaft hub can be locked with locking pin - 3359-.
  • Tensioning roller indicator is centred or maximum 5 mm to right of base plate notch.

If camshaft hub cannot be locked:

  • Pull crankshaft stop - T10050- back until pin uncovers hole.
  • Turn crankshaft out slightly past TDC by turning it in the opposite direction of engine rotation.
  • Now turn crankshaft slowly in direction of engine rotation until camshaft hub can be secured in position.
  • After locking, loosen securing nuts of camshaft pulley.

If pin of crankshaft stop - T10050- is standing on left next to hole:

  • Turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning.
  • First, tighten securing bolts of camshaft toothed belt pulley hand-tight, then tighten them to 20 Nm.

If pin of crankshaft stop - T10050- is standing on right next to hole:

  • Turn crankshaft slightly counter to engine direction of rotation again.
  • Turn crankshaft in engine direction of rotation until crankshaft stop pin arrow engages in sealing flange whilst turning.
  • First, tighten securing bolts of camshaft toothed belt pulley hand-tight, then tighten them to 20 Nm.

Continuation

  • Remove locking pin - 3359- and crankshaft stop - T10050-.
  • Turn crankshaft at least two rotations in engine direction of rotation and set to just before TDC No. 1 cylinder.
  • Repeat check.
  • If camshaft hub can be secured in position, tighten securing bolts as follows:
  • Camshaft sprocket: 45° further. Counterhold with counterhold - T10172- and adapters - T10172/4-.
  • Install middle and lower toothed belt guards.
  • Install vibration damper/belt pulley. Tighten to specified torque 10 Nm and then turn a further 90°.
  • Install poly V-belt ⇒ 13 – Crankshaft group.
  • Install upper toothed belt guard.

Further assembly is basically a reverse of the dismantling sequence. During this procedure, observe the following:

  • Ensure fuel hoses are seated correctly.
  • Do not interchange supply line and return line (return line blue or with blue marking, supply line white).
  • Install wheel housing liner.
  • Install noise insulation ⇒ General body repairs, exterior; Rep. gr. 50; Body - front; Assembly overview - noise insulation.