Removing and installing toothed belt (vehicles with engine support bolted further away from engine) — AUDI

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking pin

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• Remove coolant expansion tank and place on engine. Do not disconnect hoses.
• Turn crankshaft until marking on crankshaft pulley and tooth segment of camshaft pulley is on top. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel (arrow).
• The markings on the crankshaft pulley and the crankshaft stop must align. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.
• Mark direction of rotation of toothed belt.
• 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.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ There is a danger of fuel running out.The fuel system is under pressure.Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. — Remove engine cover panel, if fitted. To do this, pull engine cover panel upwards abruptly at front (arrows A) and then pull forwards out of rear fastening (arrow B).
2. Pull off fuel supply hose (2), fuel return hose (1) and coolant hose (3).
3. Remove connecting pipe between charge air cooler and intake connecting pipe. To do this, raise retaining clips (arrows) slightly.
4. Disconnect fuel supply line (3) and return line (2) by pulling release tabs.
5. Pull fuel filter out of its bracket or unscrew it and lay aside with hoses connected.

6. Unscrew bolt at filler neck (2) for washer fluid reservoir.
7. If fitted, unscrew bracket (3) for fuel filter.
8. Disconnect connector from coolant expansion tank (1).
9. Remove coolant expansion tank and place on engine. Do not disconnect hoses.
10. Remove poly V-belt .
11. Remove poly V-belt tensioning element.
12. Remove upper toothed belt guard.
13. Remove front right wheel housing liner General body repairs, exterior66Wheel housing liners; Front wheel housing liner.
14. Remove vibration damper/belt pulley.
15. Remove lower and centre toothed belt guards
16. Set engine to TDC No. 1 cylinder. [Note: Turn crankshaft until marking on crankshaft pulley and tooth segment of camshaft pulley is on top. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel (arrow).]
17. Lock hub with diesel injection pump locking pin3359. To do this, insert locking pin through free elongated hole on left into hole in cylinder head.
18. Lock crankshaft pulley in position with crankshaft stop T10100. To do this, push the crankshaft stop into the teeth of the toothed belt pulley from the latter's face side. [Note: The markings on the crankshaft pulley and the crankshaft stop must align. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.]
19. Mark direction of rotation of toothed belt.
20. Loosen securing bolts (1) of camshaft pulley until camshaft pulley can be moved within elongated holes.
21. Loosen tensioning roller securing nut (1).
22. Turn eccentric of tensioning roller anti-clockwise (arrow) using angle screwdriver T10264, until the tensioning roller can be locked with locking tool T10265.
23. Now turn eccentric of tensioning roller clockwise (arrow) onto stop and tighten securing nut (1) hand-tight.
24. Remove toothed belt first from coolant pump and then from remaining toothed belt 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.]
25. Turn camshaft pulley in its elongated holes to centre position (arrows).
26. Guide toothed belt through gap between engine support and engine.
27. Fit toothed belt to crankshaft pulley, tensioning roller, camshaft pulley and idler pulley.
28. Finally, fit toothed belt on coolant pump toothed belt pulley. [Note: Ensure that tensioning roller seats correctly in rear toothed belt guard (arrow).]
29. Pull out thelocking pin T10265 from the tension roller.
30. Loosen tensioning roller securing nut (1).
31. Carefully turn eccentric of tensioning roller clockwise (arrow) using angled screwdriver T10264 until indicator (2) is in the middle of gap in base plate. [Note: Ensure that securing nut does not turn as well.]
32. Hold tensioning roller in this position and tighten nut of tensioning roller.
33. Fit counterhold T10172 with pin T10172/4 as shown in illustration, and keep the toothed belt under tension on pulling side, by pressing in (direction of arrow).
34. Tighten bolts (1) of camshaft pulley.
35. Remove locking pin3359 and crankshaft stop T10100.
36. Turn crankshaft 2 rotations in direction of engine rotation until crankshaft is just before TDC again.
37. Lock camshaft hub with diesel injection pump locking pin3359 whilst turning engine in direction of engine rotation.
38. Check whether crankshaft can be locked with crankshaft stop T10100.
39. Loosen securing bolts (1) of camshaft pulley.
40. Turn crankshaft slightly against direction of engine rotation until pin of crankshaft stop is positioned just before hole in sealing flange (arrow).
41. Turn crankshaft in engine direction of rotation until crankshaft stop pin arrow engages in sealing flange whilst turning.
42. 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.
43. In this position, tighten camshaft pulley securing bolts (1).
44. Remove locking pin3359 and crankshaft stop T10100.
45. Turn crankshaft two revolutions in direction of engine rotation until crankshaft is just before TDC for No. 1 cylinder.
46. Check and, if necessary, repeat adjustment.
47. Remove middle and lower toothed belt guards.
48. Install vibration damper/belt pulley.
49. Install poly V-belt .
50. Install upper toothed belt guard.
51. Install front right wheel housing liner General body repairs, exterior66Wheel housing liner.
52. Install coolant expansion tank.
53. Install fuel filter.
54. Bolt on filler neck for window wash system.
55. Install engine cover panel.

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