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Discussion Starter #1
Hi,
I am a newbe to this forum and trying to find out the parts and special tools needed to replace the timer belt on my VW Golf Plus with a 77KW TDI engine. The car has roughly 28,000 Km on the clock but will be 5 years old next April.
The service book seems to indicate that the timer belt replacement is due at 60,000 Km or 4 years.
Any hints would be welcome.
 

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Quick question, is the injection pump driven by the engine or is it a pumpe duse injector engine?

You should be able to use the writeups for hints even though there may be differences from yours. Take a look at the FAQ section for timing belt writueps
 

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Discussion Starter #4
Quick question, is the injection pump driven by the engine or is it a pumpe duse injector engine?

You should be able to use the writeups for hints even though there may be differences from yours. Take a look at the FAQ section for timing belt writueps
Thank you for your responses. The engine code is BXE (1.9 litres). It seems to a Pump duse injector type.
I had a look at a FAQ for Mk5 and seem to understand that the belt timing needs to be fine tuned in the calculator using the diagnostic plus and appropriate software. Is this a requirement to properly tune the engine or just "nice to have" ?
 

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As long as you use the tools the engine will start and it should be about right.

It's not possible to fine tune it without seeing the value through software though.
 

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Welcome to the forum. welcometomyturbodies

Golf Plus (05-09) 1,9D TDI PD 2006-09 Engine code: BXE Copyright AD.

Replacement time: 2.5 hrs

Special tools:
Auxiliary drive belt tensioner locking pin - Volkswagen No.T10060A.
Camshaft sprocket locking tool - Volkswagen No.3359.
Camshaft sprocket holding tool - Volkswagen No.T10172.
Camshaft sprocket holding tool pins - Volkswagen No.T10172/4.
Crankshaft sprocket locking tool - Volkswagen No.T10100.
Tensioner pulley locking pin - Volkswagen No.T10265.
Tensioning tool - Volkswagen No.T10264.

Removal:
1. Raise and support front of vehicle.
2. Remove:
Engine undershield.
RH wheel arch liner.
Engine top cover.

3. Disconnect:
Fuel supply and return pipes.
Coolant expansion tank multi-plug.

4. Remove:
Turbocharger inlet hose.
Fuel filter. DO NOT disconnect pipes.
Fuel filter bracket.
Windscreen washer reservoir filler neck.
Coolant expansion tank. DO NOT disconnect hoses.
Auxiliary drive belt. Use tool No.T10060A.

NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Auxiliary drive belt tensioner.
Timing belt upper cover Fig. 1.
Crankshaft pulley bolts Fig. 2.
Crankshaft pulley Fig. 3.
Timing belt centre cover Fig. 4.
Timing belt lower cover Fig. 5.

5. Turn crankshaft clockwise to TDC on No.1 cylinder.
6. Ensure timing mark aligned with notch on camshaft sprocket hub Fig. 6.

NOTE: Notch located behind camshaft sprocket teeth.

7. Lock camshaft. Use tool No.3359 Fig. 7.
8. Lock crankshaft sprocket. Use tool No.T10100 Fig. 8.
9. Ensure timing marks aligned Fig. 9.
10. Slacken camshaft sprocket bolts Fig. 10.

NOTE: Slacken bolts until sprocket can be moved within slotted holes.

11. Slacken tensioner pulley nut Fig. 11.
12. Turn tensioner pulley anti-clockwise until locking pin can be inserted Fig. 12. Use tool No.T10264 Fig. 13.
13. Insert locking pin in tensioner pulley Fig. 14. Tool No.T10265.
14. Turn tensioner pulley fully clockwise until it reaches stop Fig. 15. Use tool No.T10264 Fig. 13.

15. Lightly tighten tensioner pulley nut Fig. 11.
16. Remove timing belt, starting at water pump sprocket.

NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation:

NOTE: Engine must be COLD.

1. Ensure camshaft sprocket locked with tool Fig. 7.
2. Ensure crankshaft sprocket locking tool located correctly Fig. 8.
3. Ensure timing marks aligned Fig. 9.
4. Ensure tensioner pulley locking pin inserted Fig. 14.
5. Ensure tensioner retaining lug is properly engaged Fig. 16.
6. Turn camshaft sprocket until bolts in centre of slotted holes.

NOTE: Sprocket should turn freely but not tilt.

7. Fit timing belt in following order:
Crankshaft sprocket.
Tensioner pulley.
Camshaft sprocket.
Guide pulley.
Water pump sprocket.

NOTE: If reusing old belt, observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.

8. Remove locking pin from tensioner pulley Fig. 14.
9. Slacken tensioner pulley nut Fig. 11.
10. Turn tensioner pulley slowly clockwise until pointer aligned with notch Fig. 17.

NOTE: Ensure tensioner pulley nut does not turn Fig.19200.11.

11. Hold tensioner pulley. Use tool No.T10264 Fig. 13.
12. Tighten tensioner pulley nut Fig. 11. Tightening torque: 20 Nm + 45°.
13. Hold camshaft sprocket. Use tool Nos.T10172/4.

NOTE: Ensure belt is taut between sprockets on non-tensioned side.

14. Tighten camshaft sprocket bolts Fig.19200.10. Tightening torque: 25 Nm.
15. Remove:
Camshaft sprocket holding tool.
Camshaft sprocket locking tool Fig. 7.
Crankshaft sprocket locking tool Fig. 8.
16. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
17. Fit camshaft sprocket locking tool while slowly turning crankshaft to TDC Fig. 7. Tool No.3359.
18. Ensure timing mark aligned with notch on camshaft sprocket hub Fig. 6.

NOTE: Notch located behind camshaft sprocket teeth.

19. Ensure crankshaft sprocket locking tool can be inserted easily Fig. 8.
20. Ensure timing marks aligned Fig. 9.
21. Ensure tensioner pulley pointer aligned with notch Fig.19200.17.
22. If crankshaft sprocket locking tool cannot be inserted Fig. 8:
Slacken camshaft sprocket bolts Fig. 10.
Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing Fig. 18.
Turn crankshaft clockwise until lug and hole aligned.
Lock crankshaft sprocket. Use tool No.T10100 Fig. 8.
Hold camshaft sprocket. Use tool Nos.T10172/4.

NOTE: Ensure belt is taut between sprockets on non-tensioned side.

Tighten camshaft sprocket bolts Fig.19200.10. Tightening torque: 25 Nm.
Remove camshaft sprocket holding tool.
Remove locking tools Fig. 7 & Fig. 8.
Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
Fit camshaft sprocket locking tool while slowly turning crankshaft to TDC Fig. 7.
Ensure crankshaft sprocket locking tool can be inserted easily Fig. 8.
Ensure timing marks aligned Fig. 9.
Ensure tensioner pulley pointer aligned with notch Fig. 17.

23. Install components in reverse order of removal.
24. Tighten crankshaft pulley bolts Fig. 2. Tightening torque: 10 Nm + 90°.
 

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Pharo the BRM timing belt replacement ''how to'' on this site is exactly the same for a BXE engine as mine is also a BXE. The only difference I found was there was no hole throught the wheel arch to remove one of the engine mount bracket bolts so had to do it from behind the arch.

http://www.myturbodiesel.com/1000q/a5/brm-VW-Jetta-TDI-timing-belt-replacement-1.htm

http://www.myturbodiesel.com/forum/f21/2005-5-2006-vw-jetta-tdi-timing-belt-installation-3006/

dont forget to do the water pump while u are down there....
 

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Discussion Starter #8
Thank you guys for your feedback.
Will put a post with my experience once I am done.
I may take a while though.
 

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Hi Keith
Have Golf (Not Plus) 2007 1.9 TDI DSG which is 4yrs old in Sept.
Thank you so much for your instructions and stating that on model/year the engine mount does not have to be removed to change timing belt.
However can I also change tensioner, roller, and water pump without removing the engine mount?
Many thanks in anticipation.
Michael (UK,Essex)
 
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