VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing toothed belt from camshafts, engine code CHPA, CZDA

Removing toothed belt from camshafts, engine code 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-
Procedure
–  Loosen hose clips -1, 2- and remove air pipe.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Move air hoses clear at air pipe.
–  Detach connector from charge pressure sender -GX26-.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Release fasteners -arrows- using release tools -T10527- and -T10527/1-.
–  Remove air pipe -1-.
  Removing toothed belt from camshafts, engine code CHPA, CZDA
–  Press release buttons and pull off hose -1-.
–  Remove bolts -arrows- and detach crankcase breather hose.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.66.
–  Drain coolant → Chapter.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  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.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Remove bolt -2-.
–  Release clips -arrows- and detach upper toothed belt guard -1-.
  Note
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.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Unscrew plug for “TDC” hole in cylinder block.
–  Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 Nm.
–  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 Nm.
Turn crankshaft in direction of engine rotation as far as stop.
On both camshafts on gearbox end the asymmetrical grooves -arrows- must be positioned right above horizontal camshaft centre line as shown in illustration.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

The grooves on the exhaust camshaft -upper arrows- can be accessed through the recesses in toothed belt pulley for coolant pump.
On the inlet camshaft the grooves -lower arrows- must also be positioned right above horizontal camshaft centre line.
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:
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Insert camshaft clamp -T10494- as far as stop into camshaft.
–  Tighten bolt -arrow- by hand.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  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.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Loosen bolts -1, 2- approx. 1 turn using counterhold -T10172- with adapter -T10172/1-.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  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.
–  Remove toothed belt from camshaft pulleys.
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:
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

Camshaft clamp -T10494- must be attached to camshaft housing.
Risk of damage to camshaft caused by improper handling.Never use the camshaft clamp for counterholding.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  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.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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.
Fit toothed belt in prescribed sequence:
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  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 Nm 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.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Tighten bolts -1, 2- initially to 50 Nm using counterhold -T10172- with adapter -T10172/1-.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Unscrew locking pin -T10340-.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

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 Nm.
–  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.
–  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:
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

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

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  While doing this, 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-, the valve timing is not correct.
–  Repeat adjustment of valve timing.
If it is possible to insert camshaft clamp -T10494-, the valve timing is correct.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Unscrew locking pin -T10340-.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Remove bolt -arrow- and detach camshaft clamp -T10494-.
–  Tighten bolts -1- and -2- to final torque setting → Chapter.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  Use counterhold -T10172- with adapter -T10172/1-.
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

–  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 -T10504- have been removed.
Further assembly is carried out in the reverse order of removal.
Specified torques
→ 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“
→ Chapter „Assembly overview - crankcase breather system“
→ Chapter „Assembly overview - coolant pump, thermostat“
→ Chapter „Assembly overview - charge air system“
 

Removing toothed belt from camshafts, engine code CHPA, CZDA

Checking valve timing, engine codes CHPA, CMBA, CPVA, CXSA, CZCA, CPVB, CZDA
Special tools and workshop equipment required     Torque wrench -VAS 6583-   ...

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- ...

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