Volkswagen Golf Service & Repair Manual: Removing toothed belt from camshafts, engine code CHPA, CZDA
| Special tools and workshop equipment required |
| Counterhold -T10172- with adapter -T10172/1- |
| Special wrench, 30 mm -T10499- |
| Insert tool, 13 mm -T10500- |
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Loosen hose clips -1, 2- and
remove air pipe. |
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Move air hoses clear at air pipe. |
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Detach connector from charge pressure sender -GX26-. |
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Release fasteners -arrows-
using release tools -T10527- and -T10527/1-. |
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Press release buttons and pull off hose
-1-. |
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Remove bolts -arrows- and
detach crankcase breather hose. |
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Remove noise insulation
→ General body repairs, exterior; Rep. gr.66. |
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Drain coolant
→ Chapter. |
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Unscrew bolts -A ... D-, and
push cover -1- for thermostat to
one side. |
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Lay wiring harness to one side
-arrows-. |
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Unscrew bolts -1, 3- and remove
cover -2- for toothed belt for
coolant pump. |
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Unscrew bolts -arrows- and
detach sealing cap -1-. |
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Separate plug-in connectors from fuel hose and from hose to
activated charcoal filter
→ Rep. gr.20. |
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Release hoses from retainer -3-
and lay them to one side. |
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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. |
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Unscrew bolts -arrows- and
remove cover from camshaft adjuster for exhaust camshaft. |
| Rotate crankshaft to “TDC” as follows: |
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Remove ignition coil 1 with output stage -N70- and cylinder
1 spark plug
→ Chapter. |
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Insert a screwdriver with a shaft length of at least 250 mm
into spark plug hole so that it contact piston crown. |
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Turn the crankshaft in the normal direction of rotation
until the piston in cylinder 1 shows “BDC”. |
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| The screwdriver moves in the
-direction of the arrow-. |
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Turn the crankshaft further, until the screwdriver has moved
-30 mm- in the
-direction of the arrows- |
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Unscrew plug for “TDC” hole in cylinder block. |
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Screw locking pin -T10340- into cylinder block as far as
stop and tighten to 30 Nm. |
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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. |
| 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: |
| 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. |
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| 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. |
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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: |
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Use assembly tool -T10487- to push against toothed belt in
-direction of arrow-. |
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Insert camshaft clamp -T10494- as far as stop into camshaft. |
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Tighten bolt -arrow- by hand. |
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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. |
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Loosen bolts -1, 2- approx. 1
turn using counterhold -T10172- with adapter -T10172/1-. |
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Loosen bolt -1- with tool
insert -T10500-. |
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Release tensioning roller on eccentric adjuster
-2- using special wrench, 30 mm
-T10499-. |
| 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. |
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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. |
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Check “TDC” position of camshaft and crankshaft: |
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| 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. |
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| 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. |
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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. |
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| The sheet-metal tab -arrow- of
the tensioning roller must engage in the cast notch of the
cylinder head. |
| 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: |
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Pull toothed belt upwards and fit it on idler pulley
-1-, tensioning roller
-2- and camshaft toothed belt
pulleys-3- and
-4-. |
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Tighten bolts -1, 2- initially
to 50 Nm using counterhold -T10172- with adapter -T10172/1-. |
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Unscrew locking pin -T10340-. |
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Remove bolt -arrow- and detach
camshaft clamp -T10494-. |
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Turn crankshaft 2 turns in direction of rotation of engine. |
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Screw locking pin -T10340- into cylinder block as far as
stop and tighten to 30 Nm. |
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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: |
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Use assembly tool -T10487- to push against toothed belt in
-direction of arrow-. |
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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. |
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Repeat adjustment of valve timing. |
| If it is possible to insert camshaft clamp -T10494-, the
valve timing is correct. |
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Unscrew locking pin -T10340-. |
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Remove bolt -arrow- and detach
camshaft clamp -T10494-. |
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Tighten bolts -1- and
-2- to final torque setting
→ Chapter. |
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Use counterhold -T10172- with adapter -T10172/1-. |
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Tighten plug -1- using
counterhold -T10172- with adapter -T10172/1-. |
| 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. |
| → 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“ |
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Special tools and workshop equipment
required
Torque wrench -VAS 6583-
...
Special tools and workshop equipment required
Torque wrench -VAS 6583-
Counterhold -T10172- with adapter -T10172/1-
Locking pin -T10340- ...
Other materials:
Run-flat tyres, structure of a PAX tyre
Run-flat tyres (PAX) are specially developed tyres that
differ from conventional tyres as follows:
PAX tyre with support ring
–
-I- Pax tyre with regular tyre
pressure
...
Removing and installing battery, vehicles without high-voltage system
Special tools and workshop equipment
required
Torque wrench -V.A.G 1331-
Torque wrench -V.A.G 1783-
...
Component protection
First read and observe the introductory information
and safety warnings Some electronic components and control units are fitted
with component protection as standard, e.g the radio or navigation system.
Component protection was developed as a protective mechanism in order to:
Prevent any ...
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Checking valve timing, engine codes CHPA, CMBA, CPVA, CXSA, CZCA, CPVB, CZDA
Removing and installing toothed belt, engine codes CHPA, CZDA