IMPORTANT: All service items are vital to the smooth running and reliability of a vehicle, none more so than the timing belt and its associated components. For this reason we have highlighted important information from the manufacturers' service schedules covering the intervals for checks and replacements. Be sure that you make the vehicle owner aware of this information. Industry best practice is to ensure that the vehicle owner is made aware of the importance of replacing the timing belt and its associated components according to the manufacturers' specification. The service history and the use of the vehicle must be considered when deciding the correct course of action. If there is any doubt to the serviceability of the belt and its components, they should be replaced.
Timing belt replacement intervals
Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt.
Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, there are several other factors which must be considered when checking a timing belt:
Is the belt an original or a replacement?
When was the belt last replaced and was it at the correct mileage?
Is the service history of the vehicle known?
Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval?
Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected?
If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due?
If the belt does fail, have you considered the consequences? If the engine is an INTERFERENCE type then considerable expensive damage may well be the result.
The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences.
If in doubt about the condition of the belt - RENEW it.
Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse operating conditions, inspection and service replacement.
Timing belt - Renew Every 80000 miles or 48 months
Timing belt tensioner - Renew Every 160000 miles or 96 months
Check For Engine Damage
CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).
Disconnect battery earth lead.
DO NOT turn crankshaft or camshaft when timing belt removed.
Remove glow plugs to ease turning engine.
Turn engine in normal direction of rotation (unless otherwise stated).
DO NOT turn engine via camshaft or other sprockets.
Observe all tightening torques.
1. Raise and support front of vehicle.
RH wheel arch liner.
Engine top cover.
Auxiliary drive belt. Use tool No.T10060 (if necessary).
Auxiliary drive belt tensioner.
Timing belt upper cover Fig. 1.
Exhaust pipe from auxiliary heater.
3. Slacken lower coolant pipe bracket bolt.
Intercooler to turbocharger hose.
Crankshaft pulley bolts Fig. 2.
Crankshaft pulley Fig. 3.
Timing belt centre cover Fig. 4.
Timing belt lower cover Fig. 5.
5. Disconnect fuel supply and return pipes.
NOTE: Supply pipe coloured black and return pipe coloured blue.
6. Remove fuel filter. DO NOT disconnect pipes.
7. Drain coolant (if necessary).
8. Disconnect coolant expansion tank top hose.
9. Remove coolant expansion tank. DO NOT disconnect hoses.
10. Turn crankshaft clockwise to TDC on No.1 cylinder.
11. Ensure window in each camshaft sprocket at 12 o'clock position Fig. 6.
12. Ensure timing mark aligned with notch on camshaft sprocket (CA2) hub Fig. 7. Notch located behind camshaft sprocket teeth.
13. Lock crankshaft sprocket.
NOTE: There are two types of crankshaft sprocket.
Type A: Use tool No.T10050 Fig.19955.A.
Type B: Use tool No.T10100 Fig.19955.B.
NOTE: Ensure lug of crankshaft sprocket locking tool located in oil seal housing.
14. Ensure timing marks aligned Fig. 8.
15. Support engine.
16. Remove RH engine mounting.
NOTE: Engine may need to be raised/lowered slightly.
17. Slacken bolts of each camshaft sprocket Fig. 9 & Fig. 10.
NOTE: Slacken bolts until sprockets can be moved within slotted holes.
18. Lock camshaft sprockets. Use tool No.3359 Fig. 11 & Fig. 12.
19. Slacken tensioner pulley nut Fig. 13.
20. Turn tensioner pulley anti-clockwise until locking pin can be inserted Fig. 14. Use tool No.T10020 Fig. 15.
21. Insert locking pin in tensioner pulley Fig. 16. Tool No.T10115.
22. Turn tensioner pulley fully clockwise until it reaches stop Fig. 17. Use tool No.T10020 Fig. 15.
23. Lightly tighten tensioner pulley nut Fig. 13.
24. Remove RH engine mounting bracket.
NOTE: RH engine mounting bracket can only be removed with timing belt slackened.
25. Remove timing belt, starting at water pump sprocket.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
NOTE: Engine must be COLD.
1. Fit new guide pulley (G1). Tightening torque: 20 Nm.
2. Fit new guide pulley (G2). Tightening torque: 40 Nm + 90Â°. Use new bolt.
3. Ensure camshaft sprockets locked with tools Fig. 11 & Fig. 12.
4. Ensure crankshaft sprocket locking tool located correctly Fig.19955.A or Fig.19955.B.
5. Ensure timing marks aligned Fig. 8.
6. Ensure tensioner pulley locking pin inserted Fig. 16. Tool No.T10115.
7. Ensure tensioner retaining lug is properly engaged Fig. 18.
8. Turn camshaft sprockets fully clockwise in slotted holes.
NOTE: Sprockets should turn freely without tilting.
9. Fit timing belt in clockwise direction, starting at crankshaft sprocket.
NOTE: If reusing old belt, observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.
RH engine mounting bracket.
RH engine mounting bracket lower bolt. Use new bolt.
NOTE: Engine may need to be raised/lowered slightly.
11. Slacken tensioner pulley nut Fig. 13.
12. Remove locking pin from tensioner pulley Fig. 16. Tool No.T10115.
13. Turn tensioner pulley slowly clockwise until pointer aligned with notch Fig. 19. Use tool No.T10020 Fig. 15.
NOTE: Ensure tensioner pulley nut does not turn Fig. 13.
19. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
20. Fit camshaft sprocket (CA1) locking tool while slowly turning crankshaft to TDC Fig. 11. Tool No.3359.
21. Ensure camshaft sprocket (CA2) locking tool can be inserted Fig. 12. Tool No.3359.
22. Ensure crankshaft sprocket locking tool can be inserted easily Fig.19955.A or Fig.19955.B. Tool No.T10050/T10100.
23. Ensure timing marks aligned Fig. 8.
24. Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch Fig. 19.
25. If camshaft sprocket (CA2) locking tool cannot be inserted Fig. 12:
26. Remove crankshaft sprocket locking tool Fig.19955.A or Fig.19955.B.
27. Slacken camshaft sprocket (CA1) bolts Fig. 9.
28. Ensure camshaft sprocket (CA1) locked with tool Fig. 11. Tool No.3359.
29. Turn crankshaft until camshaft sprocket (CA2) locking tool can be inserted Fig. 12. Tool No.3359.
30. Slacken camshaft sprocket (CA2) bolts Fig. 10.
31. Lock crankshaft sprocket. Use tool No.T10050 Fig.19955.A or T10100 Fig.19955.B.
32. Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing Fig. 20.
33. Turn crankshaft clockwise until lug of locking tool and hole aligned.
34. Hold camshaft sprocket (CA1). Use tool No.T10172.
NOTE: Ensure belt is taut between sprockets on non-tensioned side.
35. Tighten bolts of each camshaft sprocket Fig. 9 & Fig. 10. Tightening torque: 25 Nm.
36. Remove camshaft sprocket holding tool.
37. Remove camshaft sprocket locking tools Fig. 11 & Fig. 12.
38. Remove crankshaft sprocket locking tool Fig.19955.A or Fig.19955.B.
39. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
40. Fit camshaft sprocket (CA1) locking tool while slowly turning crankshaft to TDC Fig. 11. Tool No.3359.
41. Ensure camshaft sprocket (CA2) locking tool can be inserted Fig. 12. Tool No.3359.
42. Ensure crankshaft sprocket locking tool can be inserted easily Fig.19955.A or Fig.19955.B. Tool No.T10050/T10100.
43. Ensure timing marks aligned Fig. 8.
44. Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch Fig. 19.
45. Fit RH engine mounting bracket upper bolts. Use new bolts.
46. Install components in reverse order of removal.
47. Tighten crankshaft pulley bolts Fig. 2. Tightening torque: 10 Nm + 90Â°. Use new bolts.
48. Refill coolant (if necessary).
VW TDI forum, Audi, Porsche, and Chevy Cruze Diesel forum
A forum community dedicated to Audi, Volkswagen, Porsche, and all turbo diesel owners and enthusiasts. Come join the discussion about performance, modifications, troubleshooting, TDI, maintenance, and more!