(pressebox) Hannover, 15.02.2011 – Detailed instructions for the 2.0 l common rail engine in the VW Scirocco, Golf V, Golf VI, Golf Plus and Jetta III – From model year 2008 onwards – Engine code CBDB – ContiTech is demonstrating how mistakes can be prevented when changing belts
Large numbers of the 2.0 l common rail engine with the engine code CBDB are installed in various VW models. When the timing belt is changed, serious mistakes are often made. To ensure that changing the belts goes smoothly, ContiTech Power Transmission Group is providing mechanics with detailed installation tips. Step by step, the ContiTech expert explains how to replace belts correctly.
The manufacturer recommends that the timing belt and tension pulley be replaced as follows:
Scirocco:
2009 and older: every 180,000 km
2010 and newer: timing belt and tension pulley every 210,000 km
Golf Plus:
Timing belt every 180,000 km
Golf V:
Timing belt every 180,000 km
Golf VI:
Timing belt and tension pulley every 210,000 km
Jetta III:
2009 and older: every 180,000 km, tension roller every 360,000 km
2010 and newer: timing belt and tension pulley every 210,000 km
The working time is 2.20 hours for all engines.
Tip: When the timing belt is changed, the tension pulley, the idler pulley and the water pump should be replaced, too.
Fitters require the following special tools for belt changing:
Locking pin for camshaft (OE 3359)
Locking pin for high-pressure pump gear (OE 3359)
Arrester (OE T 10172, OE T 10172/4)
Lock ring tool for crankshaft (OE T 10050)
Cap wrench (OE T 10264)
Locking tool (OE T 10265)
Safety notes:
Turn the engine in the direction of engine rotation ONLY on the crankshaft gear. The crankshaft sprocket and camshaft sprocket must never be rotated after the timing belt has been removed.
Do not use camshaft locking tool(s) as an arrester when loosening or tightening the camshaft gear.
When turning the camshaft, the crankshaft may not be positioned at top dead center (OT).
The timing belt may not come in contact with oil or cooling water.
Adjustment work on the timing belt may be carried out only when the engine is cold.
Make a note of the radio code. Disconnect the battery’s negative terminal.
We recommend that, once the timing belt has been removed, it always be replaced and not reused.
Tightening torques:
Note: Self-locking nuts and bolts should always be replaced, even if not always specified by the manufacturer.
According to VW, the following nuts and bolts are to be replaced:
Bolt(s) on the camshaft gear (tightening torque central bolt: 100 Nm, gear level 1: 20 Nm, gear level 2: 90°)
Bolt(s) on the high-pressure pump gear (level 1: 20 Nm, level 2: 90°)
Nut(s) of the tension pulley (level 1: 20 Nm, level 2: 45°)
Center timing belt guard (10 Nm)
Lower timing belt guard (10 Nm)
Bolt(s) on the vibration damper (level 1: 10 Nm, level 2: 90°)
Idler pulley (50 Nm and turn an additional 90°).
Removal:
Remove engine cover.
Dismantle fuel filter.
Disconnect the plug on the coolant temperature sensor.
Open clip(s). Remove the upper timing belt guard.
Remove front right wheel-house liner.
Remove drive unit belt.
Remove vibration damper.
Remove the lower timing belt guard.
Remove the center timing belt guard.
Remove coolant pipe(s).
Position the engine at top dead center cylinder 1. Note the marking(s) (fig. 1, no. 1 and fig. 2, nos. 2 and 3). The geared segment on the timing belt gear of the camshaft must be at the top (fig. 1, no. 1).