Tech Tips
VW belt replacement guide
JOBS
Large numbers of the VW 2.0L common rail engines (engine code CBDB) are installed in
various models. When the timing belt is changed, serious mistakes are often made. To ensure
that changing belts goes smoothly, ContiTech Power Transmission Group provides a step by
step, detailed installation guide to help prevent problems along the way.
These are detailed instructions for replacing the
timing belt on the 2.0 litre common rail engine
in the VW Scirocco, Golf V, Golf VI, Golf Plus and
Jetta III. These timing belts are found from model
year 2008 onwards, and are found on engines
that bear the code CBDB.
Volkswagen recommends that the timing belt
and tension pulley be replaced as follows:
Scirocco: 2009 and older: every 180,000 km
2010 on: timing belt, 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: Timing belt every
180,000 km, tension roller every Fig. 1 Fig. 2
360,000 km
2010 on: timing belt and tension
pulley every 210,000 km
The working time is 2.2 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:
1. Locking pin for camshaft (OE 3359)
2. Locking pin for high-pressure pump
gear (OE 3359)
3. Arrester (OE T 10172, OE T 10172/4)
4. Lock ring tool for crankshaft (OE T 10050) Fig. 3
5. Cap wrench (OE T 10264)
6. 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.
Fig. 4
AUTOBIZ TECH TIPS December 2011 Compendium >> originally published in Autobiz September 2011
Adjustment work on the timing belt may be carried Remove the timing belt from the idler pulley first
out only when the engine is cold. and then from the gear wheels.
Make a note of the radio code. Disconnect the
battery's negative terminal. Installation:
We recommend that, once the timing belt has been Adjustment work on the timing belt may be carried
removed, it always be replaced and never reused. out only when the engine is cold.
Tension pulley: The nose of the base plate must be
Tightening torques: in the recess (Fig. 7, No. 1).
Note: Self-locking nuts and bolts should always be Check the top dead center marking and readjust as
replaced, even if not always specified by the required.
manufacturer. The tension pulley must be locked using the locking
tool and fixed to the stop on the right
According to VW, the following nuts and bolts are (Fig. 6, No. 2).
to be replaced: Turn the camshaft gear clockwise to the stop.
Bolt(s) on the camshaft gear (tightening torque Turn the injection pump gear clockwise to the stop.
central bolt: 100 Nm, gear level 1: 20 Nm, Position the timing belt onto the crankshaft, tension
gear level 2: 90°) pulley, camshaft gear, coolant pump, and high- Fig. 5
Bolt(s) on the high-pressure pump gear pressure pump, in that order.
(level 1: 20 Nm, level 2: 90°) Loosen the nut of the tension pulley.
Nut(s) of the tension pulley (level 1: 20 Nm, Remove special tool (locking tool).
level 2: 45°) Ensure that the tension roller is positioned correctly.
Center timing belt guard (10 Nm) Using the hex key, turn the tension pulley clockwise
Lower timing belt guard (10 Nm) (in the direction of the arrow).
Bolt(s) on the vibration damper (level 1: 10 Nm, The pointer of the tension pulley must be flush with
level 2: 90°) the recess in the base plate (Fig. 8, No. 1).
Idler pulley (50 Nm and turn an additional 90°). The nut of the tension pulley may not turn while
this is being done (Fig. 8, No. 2).
Removal: Tighten the nut of the tension pulley (Fig. 8, No. 2).
Remove engine cover. Hold the camshaft gear to maintain pretension
Dismantle fuel filter. counterclockwise (use the arrester).
Disconnect plug on the coolant temperature sensor. Tighten bolt(s) on the camshaft gear (Fig. 4, No. 2)
Open clip(s). Remove the upper timing belt guard. Tighten the bolt(s) on the high-pressure pump gear
Remove front right wheel-house liner. (Fig. 3, No. 2)
Remove drive unit belt. Remove locking pins on the high-pressure pump Fig. 6
Remove vibration damper. gear and on the camshaft pulley (Fig. 3, No. 1 and
Remove the lower timing belt guard. Fig. 4, No. 1).
Remove the center timing belt guard. Remove crankshaft lock ring tool (Fig. 2, No. 1)
Remove coolant pipe(s). Rotate the crankshaft twice in the direction of
Position the engine at top dead center cylinder 1. engine rotation.
Note the marking(s) (Fig. 1, No. 1 and Fig. 2, Nos. 2 Position the crankshaft right before the TDC of the
and 3). The geared segment on the timing belt gear first cylinder (Fig. 6).
of the camshaft must be at the top (Fig. 1, No. 1). Use lock ring tool for crankshaft (OE T 10050) (Fig.
Use lock ring tool for crankshaft (OE T 10050) (Fig. 6, No. 1).
2, No. 1). Turn crankshaft until the lock ring tool can be used.
Markings of the crankshaft and the lock ring tool for The pin on the crankshaft lock ring tool must be
crankshaft must align (Fig. 2, Nos. 2 and 3). directly in front of the bore hole of the sealing
Lock ring tool for crankshaft: Pins must be flange (Fig. 6, No. 1).
positioned flush in the bore hole. Turn crankshaft until the lock ring tool can be used
Use locking pins on the high-pressure pump gear (Fig. 6).
and on the camshaft (Fig. 3, No. 1 and Fig. 4, No. Check whether the camshaft can be locked with the
1). lock ring tool. Fig. 7
Loosen the bolts on the high-pressure pump gear The pointer of the tension pulley must be flush with
(Fig. 3, No. 2) the recess in the base plate.
Loosen the bolts on the camshaft gear (Fig. 4, No. 2) Tighten bolt(s) on the camshaft gear.
Use arrester. Tighten bolt(s) on the injection pump gear.
Loosen the nut of the tension pulley (Fig. 5, No. 1 The rest of the installation procedure takes place as
and Fig. 6, No. 1). for the disassembly procedure, in the reverse order.
Using the hex key, turn the eccentric of the tension Mount the drive unit belt.
roller (Fig. 5, No. 3 and Fig. 6, No. 2) Decode the radio, program the volatile memory.
counterclockwise, until the tension roller can be Start the engine and check for proper function.
disconnected with the special tool (Fig. 5, No. 2). Read error memory.
Cap wrench (OE T 10264). Carry out a test drive.
Locking tool (OE T 10265) Document timing belt change.
Using the hex key, turn the tension pulley clockwise
(max. load stop, Fig. 6, No. 2).
Tighten the nut of the tension pulley slightly (Fig. 5,
No. 1 and Fig. 6, No. 1).
Fig. 8
AUTOBIZ TECH TIPS December 2011 Compendium >> originally published in Autobiz September 2011
