Engine code BBW

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Fig 1: Identifying Special Tools - Toothed Belts (Engine Code BBW)

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(Adjusting valve timing)

Special tools and equipment

10-222A Engine support bracket with legs 10-222A/1
2065 A Adjustment bar
V.A.G 1331 Torque wrench (5 to 50 Nm)
V.A.G 1332 Torque wrench (40 to 200 Nm)

T10004 Two hole pin wrench
T10172 Counterhold tool

Special tools and equipment

Fig 2: T10172/3 Pin

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T10172/3 Pin

NOTE:

If the toothed belt is to be taken off the camshaft sprocket, e.g. when removing the camshaft or the cylinder head, the following must be considered:
Engine bracket, tensioning element for ribbed belt, vibration damper/belt pulley and toothed belt guard (except for upper part) can remain installed.
To remove the toothed belt from the camshaft sprocket, unscrew the tensioning roller and slide up to the engine bracket.

Counterhold tool T10172

Fig 3: Identifying Counterhold Tool T10172, Pins T10172/1 & Pins T10172/3

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Unscrew pins T10172/1.
Screw pins T10172/3 in and tighten.

Removing

Remove engine cover.
Remove right side sound insulation.

Refer to BODY, FRONT

Remove poly V-belt. Refer to Poly V-belt, removing and installing .
Remove tensioning element for poly V-belt.
Remove intake manifold upper part. Refer to Intake manifold upper part, removing and installing .
Remove toothed belt guard upper part.

Remove coolant expansion tank (supply hose remains connected, close union for return supply hose).
Remove power steering reservoir (hoses remain connected).
Disconnect connector of camshaft timing adjustment valve.
Remove cylinder head cover.

Fig 4: Mounting Support 10-222A With Legs 10-222A/1

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Mount support 10-222A with legs 10-222A/1 as shown.

Fig 5: Locating Securing Bolts From Assembly Mounting/Engine Bracket, Assembly Mounting/Body And Assembly Mounting Bracket/Body

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Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body, and assembly mounting bracket/body (arrows) and remove assembly mounting complete.

NOTE:

Only remove the engine mounting when the engine is secured with the support bracket 10-222A.
The engine bracket must be only released when the engine mounting is removed.

Fig 6: Removing/Installing Vibration Damper/Belt Pulley

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Remove vibration damper/belt pulley.

Fig 7: Identifying Engine Bracket-To-Cylinder Head Bolts

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Remove engine bracket from cylinder block.

NOTE: When loosening the front engine mounting bolt the engine must be raised slightly with the support device.

Remove toothed belt guard center and lower parts.
Mark direction of rotation of toothed belt.

Fig 8: Identifying Adjustment Bar 2065 A

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Turn crankshaft until camshaft is set to TDC No. 1 cylinder. Adjustment bar 2065 A must be pushed into slot of camshaft.
Remove tool.
Release tensioner and take off toothed belt.
Turn crankshaft against engine direction of rotation 45 °.

Installing

Requirements

Pistons must not be positioned at TDC.
Engine must only be hand touch warm.

Tensioning toothed belt and adjusting valve timing

NOTE:

When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
Never use the adjustment bar 2065 A as counter-hold when loosening and tightening the camshaft sprocket! Use counterhold tool T10172 with pin T10172/3.

Fig 9: Locating Camshaft Sealing Plug

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Place a flat container under camshaft sprocket to collect oil leaking out when sealing plug -1- is loosened.
Unscrew sealing plug -1- carefully and collect leaking oil. Do not rotate crankshaft, if possible.

NOTE: To loosen the sealing plug use counterhold tool T10172 with pin T10172/3, if necessary.

Clean oil from camshaft sprocket with a cloth.
Remove camshaft pulley bolt. Do not rotate crankshaft, if possible.

Fig 10: Loosening Camshaft Bolt Using Counterhold Tool T10172 With Pin T10172/3

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Use counterhold tool T10172 with pin T10172/3 to loosen camshaft bolt.
Take camshaft sprocket off camshaft and clean it.

NOTE:

The teeth of the camshaft sprocket and the running surface of the camshaft must be free of oil.
In this condition, replacement of the camshaft seal is recommended as a preventative and inexpensive measure, refer to Camshaft oil seal, replacing .

Install camshaft sprocket again and camshaft bolt.

Fig 11: Identifying Adjustment Bar 2065 A

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Set camshaft to TDC No. 1. Cyl. and insert adjustment bar 2065 A.
Loosen camshaft bolt until camshaft sprocket can be turned by hand. Use counterhold tool T10172 with pin T10172/3.
Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation).

Install toothed belt guard center and lower parts and belt pulley/vibration damper.

Fig 12: Aligning Notch On Belt Pulley/Vibration Damper With Notch On Toothed Belt Guard, Upper Part

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Turn crankshaft in engine direction of rotation again at TDC No. 1 Cyl. Notch -2- on belt pulley/vibration damper must align with notch -1- on toothed belt guard, upper part.
Turn camshaft sprocket so that counterhold tool T10172 with pin T10172/3 can be inserted.
Place toothed belt on tensioning roller and camshaft sprocket.

Fig 13: Releasing Tension On Toothed Belt Until Notch And Indicator Align (Engine code BBW)

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Turn tensioning roller on eccentric with two hole pin wrench (T10004) five times onto limit stop in both directions.
Tension toothed belt by turning eccentric to left (direction of arrow) with two hole pin wrench (T10004) onto limit stop.
Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).
Tighten securing nut to 20 Nm.

Check TDC of crankshaft again, correct if necessary.

NOTE: If the crankshaft is positioned after TDC No. 1 cylinder turn the crankshaft again a bit against the engine direction of rotation and set to TDC No. 1 cylinder.

Fig 14: Tightening Camshaft Bolt While Holding Crankshaft Sprocket With Counterhold T10172 (Pin T10172/3)

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Hold crankshaft sprocket with counterhold T10172 (pin T10172/3) and tighten camshaft bolt to 40 Nm.
Remove setting bar 2065 A.
Counter-hold camshaft sprocket and tighten camshaft bolt to 130 Nm.

Fig 15: Identifying Adjustment Bar 2065 A

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Turn crankshaft two rotations in engine direction of rotation until setting bar 2065 A can be inserted.

NOTE:

It is essential that the last 45 ° (1/8 turn) is performed without stopping.
If the crankshaft has been turned to far, turn the crankshaft 1/4 turn back and set the camshaft to TDC No. 1 cylinder again (insert the setting bar 2065 A).

Fig 16: Aligning Notch On Belt Pulley/Vibration Damper With Notch On Toothed Belt Guard, Upper Part

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Check TDC of crankshaft.

Notch -2- on vibration damper/belt pulley must be positioned -a- (max. 5 mm) after TDC marking -1- on toothed belt guard lower part.

If the crankshaft is not in this area:

Repeat adjustment.

If the crankshaft is in this area:

Fig 17: Releasing Tension On Toothed Belt Until Notch And Indicator Align (Engine code BBW)

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Check toothed belt tension again and adjust if necessary.

Specification: Indicator and notch align

Continuation, completing installation of toothed belt

Fig 18: Identifying Crankshaft Sealing Plug

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Install sealing plug -1- (replace O-ring).

Tightening torque: 25 Nm

Install engine mounting to cylinder block.

Tightening torque: 45 Nm

NOTE:

Insert bolts into engine bracket before installing engine bracket.
Tighten all bolts of the engine bracket, with the tightening torque mentioned, before installing the engine mounting.

Install engine assembly mountings complete.
Align assembly mountings for engine and transmission. Refer to Engine and transmission mountings, aligning .

Tightening torques for assembly mounting. Refer to Assembly mounting .

Remove engine support device 10-222 A.
Install toothed belt guard upper part.
Install poly V-belt tensioning element.

Tightening torque: 25 Nm

Install poly V-belt. Refer to Poly V-belt, removing and installing .
Install coolant expansion tank.
Install power steering reservoir.
Install cylinder head cover.

Connect connector of camshaft timing adjustment valve.
Install intake manifold upper part. Refer to Intake manifold upper part, removing and installing .
Start engine and run briefly at idling speed (oil pressure increase in camshaft adjustment).
Install right side sound insulation:

Refer to BODY, FRONT

Check engine oil level and top off, if necessary.
Install engine cover.