Volkswagen Golf Service & Repair Manual: Removing and installing toothed belt, engine codes CHPA, CZDA

Special tools and workshop equipment required

Torque wrench -VAS 6583-

Counterhold -T10172- with adapter -T10172/1-

Locking pin -T10340-

Counterhold -T10475-

Special wrench, 30 mm -T10499-

Insert tool, 13 mm -T10500-

Assembly tool -T10487-

Camshaft clamp -T10494-

Release tool -T10527-

Release tool -T10527/1-

Removing

Loosen hose clips -1, 2- and remove air pipe.
Move air hoses clear at air pipe.
Detach connector from charge pressure sender -GX26-.

Release fasteners -arrows- using release tools -T10527- and -T10527/1-.
Remove air pipe -1-.

Press release tabs and disconnect hose -1- for activated charcoal filter.
Remove bolts -arrows- and detach crankcase breather hose.
Remove noise insulation → General body repairs, exterior; Rep. gr.66.
Drain coolant → Chapter.

Unscrew bolts -A ... D-, and push cover -1- for thermostat to one side.

Lay wiring harness to one side -arrows-.
Unscrew bolts -1, 3- and remove cover -2- for toothed belt for coolant pump.

Unscrew bolts -arrows- and detach sealing cap -1-.
Separate plug-in connectors from fuel hose and from hose to activated charcoal filter → Rep. gr.20.

Release hoses from retainer -3- and lay them to one side.
Remove bolt -2-.
Release clips -arrows- and detach upper toothed belt guard -1-.

Rotate crankshaft to “TDC” as follows:

Remove ignition coil 1 with output stage -N70- and cylinder 1 spark plug → Chapter.
Insert a screwdriver with a shaft length of at least 250 mm into spark plug hole so that it contact piston crown.
Turn the crankshaft in the normal direction of rotation until the piston in cylinder 1 shows “BDC”.

The screwdriver moves in the -direction of the arrow-.

Turn the crankshaft further, until the screwdriver has moved -30 mm- in the -direction of the arrows-

Unscrew plug for “TDC” hole in cylinder block.
Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 N·m.
Rotate crankshaft in normal direction of rotation as far as stop.

The locking pin now rests against the crank web.

Note

Locking pin -T10340- locks crankshaft in direction of engine rotation only.

Risk of damage to engine

If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position!

In this case, proceed as follows:

Unscrew locking pin.

Turn crankshaft 90° in direction of engine rotation.

Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 N·m.

Turn crankshaft in direction of engine rotation as far as stop.

To protect the toothed belt, place a cloth under the camshaft adjuster and tensioning roller to catch the engine oil which runs out. The contact points between the toothed belt and components such as camshaft pulleys, crankshaft pulley, tensioning roller and idler pulley must be free of oil.

Unscrew bolts -arrows- and remove cover from camshaft adjuster for exhaust camshaft.

On both camshafts on gearbox end the asymmetrical grooves -arrows- must be positioned right above horizontal camshaft centre line as shown in illustration.

The grooves on the exhaust camshaft -upper arrows- can be accessed through the recesses in toothed belt pulley for coolant pump. On inlet camshaft, grooves -bottom arrows- must be positioned above centre of camshaft.

A -	Exhaust camshaft

E -	Inlet camshaft

If camshafts are not positioned as described, unscrew locking pin -T10340-, turn crankshaft one rotation further and return to “TDC” position.

Note

The camshaft clamp -T10494- must slide into position easily.

Do not knock camshaft clamp into place with any kind of tool.

If the camshaft clamp -T10494- does not easily slide into position:

Use assembly tool -T10487- to push against toothed belt in -direction of arrow-.

Removing and installing toothed belt, engine codes CHPA, CZDAN15-10885

While doing this, insert camshaft clamp -T10494- into camshafts as far as stop and hand-tighten with bolt -arrow-.
Remove vibration damper → Chapter.

Unscrew bolts -arrows- and remove toothed belt guard.

Unscrew plug -1- on camshaft sprocket on intake side using counterhold -T10172- with adapter -T10172/1-.

Risk of damage to camshaft caused by improper handling.Never use the camshaft clamp for counterholding.

Loosen bolts -1- and -2- by approx. 1 turn using counterhold -T10172- with adapter -T10172/1-.

Before removing toothed belt, mark direction of rotation with chalk or felt tipped pen for installation purposes.

Loosen bolt -1- with tool insert -T10500-.
Release tensioning roller on eccentric adjuster -2- using special wrench, 30 mm -T10499-.

Risk of damage to engine

Risk of damage to the toothed belt.

The toothed belt is made of glass fibre fabric.

Therefore, bends in the toothed belt must not be smaller than 50 mm in diameter.

Otherwise the service life of the toothed belt will be reduced.

The contact points between the toothed belt and components such as camshaft pulleys, crankshaft pulley, tensioning roller and idler pulley must be free of oil.

Remove toothed belt.

Detach crankshaft pulley -1--arrow-.

Installing (adjusting valve timing)

Note

Renew bolts that are tightened with specified tightening angle.

Renew O-ring of plug if damaged.

Check “TDC” position of camshaft and crankshaft:

Camshaft clamp -T10494- fitted on camshaft housing.

Risk of damage to camshaft caused by improper handling.Never use the camshaft clamp for counterholding.

Locking pin -T10340- screwed into cylinder block as far as stop and tightened to 30 N·m. Crankshaft has been turned in direction of engine rotation until it rests against locking pin -T10340- = “TDC” position.

Renew bolts -1- and -2- for camshaft pulleys and screw them in loosely.

It should just be possible to turn the adjusters on the camshafts but no rocking is permissible.

The sheet-metal tab -arrow- of the tensioning roller must engage in the cast notch of the cylinder head.

Fit crankshaft sprocket onto crankshaft.

The contact surface between vibration damper and crankshaft pulley must be free of oil and grease. The machined surface -arrow- of crankshaft pulley must be positioned over the machined surface of the crankshaft journal.

Fit toothed belt first on crankshaft pulley from below.

Install lower toothed belt guard -arrows-.
Install vibration damper → Chapter.

Removing and installing toothed belt, engine codes CHPA, CZDAA13-10975

Renew bolts -1- and -2- for camshaft pulleys and screw them in loosely.

It should just be possible to turn the adjusters on the camshafts but no rocking is permissible.

The sheet-metal tab -arrow- of the tensioning roller must engage in the cast notch of the cylinder head.

Risk of damage to engine

Risk of damage to the toothed belt.

The toothed belt is made of glass fibre fabric.

Therefore, bends in the toothed belt must not be smaller than 50 mm in diameter.

Otherwise the service life of the toothed belt will be reduced.

The contact points between the toothed belt and components such as camshaft pulleys, crankshaft pulley, tensioning roller and idler pulley must be free of oil.

Fit toothed belt in prescribed sequence:

Pull toothed belt upwards and fit it on idler pulley -1-, tensioning roller -2- and camshaft toothed belt pulleys-3- and -4-.

Using special wrench, 30 mm -T10499-, turn eccentric adjuster -2- of tensioning roller in direction of -arrow- until adjustment indicator -3- is positioned approx. 10 mm to the right of adjustment window.
Turn eccentric adjuster back until adjustment indicator is positioned exactly in adjustment window.

Note

Torque wrench -VAS 6583- must be used for tightening.

When setting the specified torque on the torque wrench -VAS 6583-, the length indicated on insert tool, 13 mm -T10500- must be entered in the torque wrench.

Hold eccentric in that position and tighten bolt -1- to 25 N·m using insert tool -T10500- with torque wrench -VAS 6583-.

Note Turning the engine further or running the engine may lead to slight differences in the position of the adjustment indicator -3- in relation to the adjustment window. This does not affect the toothed belt tension or the timing.

Tighten bolts -1, 2- initially to 50 N·m using counterhold -T10172- with adapter -T10172/1-.

Unscrew locking pin -T10340-.

Remove bolt -arrow- and detach camshaft clamp -T10494-.

Checking valve timing:

Turn crankshaft 2 turns in direction of rotation of engine.
Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 N·m.
Rotate crankshaft further in direction of engine rotation as far as stop.

The locking pin now rests against the crank web.

Note

Locking pin -T10340- locks crankshaft in direction of engine rotation only.

Note

It should be possible to insert the camshaft clamp -T10494- easily.

Do not knock camshaft clamp into place with any kind of tool.

If the camshaft clamp -T10494- does not easily slide into position:

Use assembly tool -T10487- to push against toothed belt in -direction of arrow-.

Insert camshaft clamp -T10494- into camshafts as far as stop and hand-tighten with bolt -arrow-.

If it is not possible to insert camshaft clamp -T10494-, valve timing is not OK.

Repeat adjustment of valve timing.

If it is possible to insert camshaft clamp -T10494-, valve timing is OK.

Unscrew locking pin -T10340-.

Remove bolt -arrow- and detach camshaft clamp -T10494-.

Tighten bolts -1- and -2- to final torque → Chapter. Use counterhold -T10172- with adapter -T10172/1- for this.

Tighten plug -1- using counterhold -T10172- with adapter -T10172/1-.

Risk of damage to engine

After completing work, check that locking pin -T10340- and camshaft clamp -T10494- have been removed.

Further assembly is carried out in the reverse order of removal.

Specified torques

→ Chapter „Assembly overview - poly V-belt drive“

→ Chapter „Assembly overview - toothed belt cover“

→ Chapter „Assembly overview - toothed belt“

→ Fig. „“Plug for TDC drilling in cylinder block - specified torque”“

→ Chapter „Assembly overview - camshaft housing, engine codes CHPA, CMBA, CPVA, CXSA, CZCA, CPVB, CZDA“

Removing and installing toothed belt, engine codes CHPA, CZDA

Special tools and workshop equipment required

Torque wrench -VAS 6583-

Counterhold -T10172- with adapter -T10172/1-

Locking pin -T10340-

Counterhold -T10475-

Special wrench, 30 mm -T10499-

Insert tool, 13 mm -T10500-

Assembly tool -T10487-

Camshaft clamp -T10494-

Release tool -T10527-

Release tool -T10527/1-

Removing

Rotate crankshaft to “TDC” as follows:

The screwdriver moves in the -direction of the arrow-.

The locking pin now rests against the crank web.

Locking pin -T10340- locks crankshaft in direction of engine rotation only.

Risk of damage to engine

In this case, proceed as follows:

Unscrew locking pin.

Turn crankshaft 90° in direction of engine rotation.

Turn crankshaft in direction of engine rotation as far as stop.

The camshaft clamp -T10494- must slide into position easily.

Do not knock camshaft clamp into place with any kind of tool.

If the camshaft clamp -T10494- does not easily slide into position:

Risk of damage to engine

Risk of damage to the toothed belt.

The toothed belt is made of glass fibre fabric.

Otherwise the service life of the toothed belt will be reduced.

Installing (adjusting valve timing)

Renew bolts that are tightened with specified tightening angle.

Renew O-ring of plug if damaged.

Camshaft clamp -T10494- fitted on camshaft housing.

Risk of damage to engine

Risk of damage to the toothed belt.

The toothed belt is made of glass fibre fabric.

Otherwise the service life of the toothed belt will be reduced.

Fit toothed belt in prescribed sequence:

Torque wrench -VAS 6583- must be used for tightening.

Checking valve timing:

The locking pin now rests against the crank web.

Locking pin -T10340- locks crankshaft in direction of engine rotation only.

It should be possible to insert the camshaft clamp -T10494- easily.

Do not knock camshaft clamp into place with any kind of tool.

If the camshaft clamp -T10494- does not easily slide into position:

If it is possible to insert camshaft clamp -T10494-, valve timing is OK.

Risk of damage to engine

Further assembly is carried out in the reverse order of removal.

Specified torques

→ Chapter „Assembly overview - poly V-belt drive“

→ Chapter „Assembly overview - toothed belt cover“

→ Chapter „Assembly overview - toothed belt“

→ Fig. „“Plug for TDC drilling in cylinder block - specified torque”“

→ Chapter „Assembly overview - crankcase breather system“

→ Chapter „Assembly overview - coolant pump, thermostat“

→ Chapter „Assembly overview - turbocharger“

→ Chapter „Assembly overview - charge air system“

Test yourself