Removing and installing toothed belt, vehicles ► 12.05 — AUDI

🧭 Before you start

Fits: VW Transporter T5 (7H), VW Transporter T5 (7J)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Renewed: securing bolts

Don't miss

• The assembly mounting may only be removed if the engine is supported with support bracket10 - 222 A!The engine bracket must be loosened only when the assembly mounting has been removed.
• When loosening both upper engine bracket bolts the engine must be raised slightly with the support bracket.When loosening the lower engine bracket bolt the engine must be lowered slightly with the support bracket.
• Turn crankshaft until marking on crankshaft toothed belt pulley and tooth segment of camshaft pulley is on top. The arrow on the rear toothed belt guard must align with the markings on the camshaft sender wheel (arrows).
• The markings on the crankshaft toothed belt pulley and the crankshaft stop must align. At the same time, the pin of the crankshaft stop T10050 must engage in the drilling in the sealing flange.
• Mark direction of rotation of toothed belt.

🔧 Engine codes this applies to

📐 38 workshop diagrams for AXB

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove bulkhead on left and right General body repairs, exterior50Plenum chamber bulkhead.
2. Unbolt right cover and battery cover from lock carrier 63.
3. Remove any noise insulation General body repairs, exterior50Body, front; Noise insulation.
4. Remove charge air pipe (1) between charge air cooler and turbocharger.
5. Carefully cover or seal open ends.

6. Remove connecting hose (1) from air filter and crankcase breather hose (2).
7. Remove poly V-belt .
8. Remove pin from poly V-belt tensioning element.
9. Remove tensioning element .
10. Remove upper toothed belt guard.
11. Remove vibration damper/belt pulley .
12. Unclip cover caps on suspension strut turret.
13. Fit adapter10 - 222 A /23(1) on foremost suspension strut turret and on lock carrier (arrows).
14. Bolt support bracket10 - 222 A to respective adapter10-222A/23
15. Support engine on lifting eyes on cylinder head, using adapter10 - 222 A /23 and adapter10 - 222 A /16
16. Remove securing bolts from assembly mounting to engine bracket, assembly mounting to body (arrows) and completely remove assembly mounting. [Note: The assembly mounting may only be removed if the engine is supported with support bracket10 - 222 A!The engine bracket must be loosened only when the assembly mounting has been removed.]
17. Unbolt engine bracket from cylinder block (arrows) and remove. [Note: When loosening both upper engine bracket bolts the engine must be raised slightly with the support bracket.When loosening the lower engine bracket bolt the engine must be lowered slightly with the support bracket.]
18. Remove centre and lower toothed belt guards.
19. Set engine to TDC No. 1 cylinder. [Note: Turn crankshaft until marking on crankshaft toothed belt pulley and tooth segment of camshaft pulley is on top. The arrow on the rear toothed belt guard must align with the markings on the camshaft sender wheel (arrows).]
20. Lock hub with diesel injection pump locking pin3359. To do this, insert locking pin3359 through free elongated hole on left into hole in cylinder head.
21. Lock crankshaft toothed belt pulley in position with crankshaft stop T10050. To do this, push crankshaft stop T10050 into teeth of toothed belt pulley from latter's face side. [Note: The markings on the crankshaft toothed belt pulley and the crankshaft stop must align. At the same time, the pin of the crankshaft stop T10050 must engage in the drilling in the sealing flange.]
22. Mark direction of rotation of toothed belt.
23. Loosen securing bolts (1) of camshaft pulley until camshaft pulley can be moved within elongated holes.
24. Loosen tensioning roller securing nut. [Note: From 01.06 ►, a new toothed belt tensioner is installed. The tensioner has an additional hexagon hole (arrow). Use angle driver T10264 instead of 2-hole pin wrench T10020 to loosen and tension the toothed belt. This does not alter the procedure.]
25. Turn 2-hole pin wrench T10020 anti-clockwise until toothed belt tensioning roller can be locked using locking pin T10115.
26. Turn 2-hole pin wrench T10020 clockwise as far as stop and hand-tighten securing nut (1).
27. Remove toothed belt first from coolant pump and then from remaining toothed pulleys. [Note: Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.]
28. Turn camshaft pulley in its elongated holes to centre position (arrows).
29. Fit toothed belt to crankshaft toothed belt pulley, tensioning roller, camshaft pulley and idler roller.
30. Finally, fit toothed belt on coolant pump toothed belt pulley. [Note: Ensure that belt tensioner seats correctly in rear toothed belt guard (arrow).]
31. Undo securing nuts of tensioning roller and pull out locking pin T10115. [Note: From 01.06 ►, a new toothed belt tensioner is installed. The tensioner has an additional hexagon hole (arrow). Use angle driver T10264 instead of 2-hole pin wrench T10020 to loosen and tension the toothed belt. This does not alter the procedure.]
32. Now carefully turn tensioning roller clockwise using 2-hole pin wrench T10020 until indicator is in middle of gap in base plate (arrow).
33. Hold tensioning roller in this position and tighten securing nut of tensioning roller.
34. Fit counterhold T10172 with pin T10172/4 as shown. Press counter-hold tool T10172 in direction of arrow and keep camshaft sprocket in pretensioning position.
35. In this position, tighten camshaft pulley securing bolts (1).
36. Remove locking pin3359 and crankshaft stop T10050.
37. Turn crankshaft two revolutions in direction of engine rotation until crankshaft is just before TDC for No. 1 cylinder.
38. Lock hub with locking pin3359 whilst turning engine in direction of rotation.
39. Check whether crankshaft can be locked with crankshaft stop T10050.
40. Loosen securing bolts (1) of camshaft pulley.
41. Turn crankshaft slightly against direction of engine rotation until pin of crankshaft stop T10050 is positioned just before hole in sealing flange (arrow).
42. Now turn crankshaft in direction of engine rotation until pin of crankshaft stop T10050 engages in sealing flange whilst turning.
43. Fit counterhold T10172 with pin T10172/4 as shown. Press counter-hold tool T10172 in direction of arrow and keep camshaft pulley in pretensioning position.
44. In this position, tighten camshaft pulley securing bolts (1).
45. Remove locking pin3359 and crankshaft stop T10050.
46. Turn crankshaft two revolutions in direction of engine rotation until crankshaft is just before TDC for No. 1 cylinder.
47. Repeat measurement.
48. Install lower toothed belt guard and vibration damper/belt pulley .
49. Install middle toothed belt guard.
50. Using new securing bolts (arrows), mount engine bracket on cylinder block and tighten securing bolts. [Note: Before installing assembly mounting, tighten all engine bracket bolts to specified torque.]
51. Install assembly mounting between engine and body (renew securing bolts) .
52. Fit engine assembly mounting to engine bracket by bringing contact surfaces together using support bracket10 - 222 A and tighten .
53. Install poly V-belt .
54. Install tensioning element .
55. Install upper toothed belt guard.
56. Install charge air cooler/turbocharger and air filter/turbocharger connecting pipes.
57. Install any noise insulation General body repairs, exterior50Noise insulation.
58. Install bulkhead on left and right General body repairs, exterior50Plenum chamber bulkhead.
59. Install right cover and battery cover on lock carrier.

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