1.4 TSI engine (EA211) · Cylinder head, valve gear · Toothed belt drive
Removing toothed belt from camshaft
Special tools and workshop equipment required
- Torque wrench - VAS 6583-
- Counterhold - T10172- with adapter -T10172/1-
- Locating bolt - T10340-
- Counter-hold tool - T10475-
- Special wrench, 30 mm - T10499-
- Insert tool - T10500-
- Release tool - T10527-
- Release tool - T10527/1-
Removing
- Set piston of no. 1 cylinder to “TDC” position. ⇒ 4.7 Setting piston to TDC position
- Remove upper part of toothed belt guard ⇒ 2.3.1 Removing and installing upper toothed belt guard.
- Remove lower toothed belt guard ⇒ 2.3.2 Removing and installing lower toothed belt guard.
- Loosen plug and securing bolt for camshaft adjuster on inlet side ⇒ 3.3 Removing and installing camshaft adjuster.
Exhaust side with toothed belt sprocket
- Loosen securing bolt of toothed belt pulley on exhaust side by approx. one turn ⇒ 3.4 Removing and installing toothed belt pulley.
Exhaust side with camshaft adjuster
- Loosen securing bolt of camshaft adjuster on exhaust side by approx. one turn ⇒ 3.3.3 Removing and installing camshaft adjuster for exhaust camshaft.
Continuation for all vehicles
- Loosen securing bolt of tensioning roller -1- using insert tool, 13 mm - T10500-.
- Release tension on tensioning roller at eccentric -2- using wrench - T10499-.
- Remove toothed belt.
- Detach crankshaft pulley -1- -arrow-.
Bend radius of toothed belt
| NOTICE |
Risk of damage to toothed belt by bending it excessively. The toothed belt is made of glass fibre fabric which will be damaged if it is bent excessively.
- Never bend toothed belt to a radius less than r = 25 mm.
Installing
- Fit toothed belt -1- together with crankshaft pulley -2- onto crankshaft journal.
- Milled surface of crankshaft sprocket -arrow- must be positioned on milled surface of crankshaft stub.
- Contact surface between poly V-belt pulley and crankshaft toothed belt pulley must be free of oil and grease.
Exhaust side with toothed belt sprocket
- Renew bolt -2- and screw in loosely.
- Renew bolt -1- and screw in loosely.
Exhaust side with camshaft adjuster
- Renew bolt -2- and screw in loosely.
- Renew bolt -1- and screw in loosely.
Continued for all vehicles
- It should just be possible to turn camshaft pulleys on camshafts but no rocking is permissible.
- Metal tab -arrow- of tensioning roller must engage in recess in cylinder head.
Fit toothed belt in prescribed sequence:
- Pull toothed belt upwards and fit on idler pulley -1-, tensioning roller -2- and camshaft toothed belt pulleys -3- and -4-.
- Rotate eccentric -2- of tensioning roller using special wrench, 30mm -T10499- in -direction of arrow- until adjustment pointer -3- is located approx. 10 mm to the right from adjustment window.
- Turn eccentric adjuster back until adjustment indicator is positioned exactly in adjustment window.
- Hold eccentric in that position and tighten bolt -1- to 25 Nm using insert tool - T10500- with torque wrench - VAS 6583-.
- Install lower part of toothed belt guard ⇒ 2.3.2 Removing and installing lower toothed belt guard.
- Tighten camshaft adjuster on inlet camshaft to specified initial torque ⇒ Fig. ““”“, page 166.
Exhaust side with toothed belt sprocket
- Tighten toothed belt sprocket of exhaust camshaft to specified initial torque ⇒ 3.4 Removing and installing toothed belt pulley.
Exhaust side with camshaft adjuster
- Tighten camshaft adjuster of exhaust camshaft to specified initial torque ⇒ 3.4 Removing and installing toothed belt pulley.
Continued for all vehicles
- Check valve timing ⇒ 2.5 Checking valve timing.
- Adjust valve timing ⇒ 2.6 Adjusting valve timing.
- Tighten camshaft adjuster on inlet camshaft to specified final torque ⇒ Fig. ““”“, page 166.
Exhaust side with toothed belt sprocket
- Tighten toothed belt sprocket of exhaust camshaft to specified final torque ⇒ 3.4 Removing and installing toothed belt pulley.
Exhaust side with camshaft adjuster
- Tighten camshaft adjuster of exhaust camshaft to specified final torque. ⇒ 3.3.3 Removing and installing camshaft adjuster for exhaust camshaft
Further assembly is carried out in the reverse order of removal.
Specified torques:
- ⇒ 1.1 Assembly overview - poly V-belt drive
- ⇒ 2.1 Assembly overview - toothed belt cover
- ⇒ 2.2 Assembly overview - toothed belt
- ⇒ Fig. ““Plug for TDC drilling in cylinder block at rear – specified torque”“, page 52
- ⇒ 1.2 Assembly overview - camshaft housing
- ⇒ 3.1 Assembly overview - crankcase breather system
- ⇒ 2.1 Assembly overview - coolant pump, thermostat
- ⇒ 1.1 Assembly overview - turbocharger
- ⇒ 2.1 Assembly overview - charge air system
- ⇒ General body repairs, exterior; Rep. gr. 66; Noise insulation; Assembly overview - noise insulation