Timing belt kit including water pump

Transcription

1 FORD VAG Issue VKMC Timing belt kit including water pump Over the years, the automotive industry has seen the timing system in many makes and models of cars become more and more complex. One example of these changes has been the inclusion of the water pump in this system. Good technicians will always change the water pump when carrying out a service on the timing system. At the first scheduled belt change, the water pump will have covered the same mileage/kilometers as the rest of the system. By not replacing the pump, the garage is taking a risk by assuming that the pump will last through to the next scheduled timing system change. The technician must consider the fact that the grease in the pump will have deteriorated due to the constant fluctuation of the engine temperature, speed of rotation and the age of the pump. Also, by re-tensioning the pump with a new belt, the seal and the bearings will now have a more robust angular tension placed upon them this could also cause a future leak. The VKMC kit has all of the components needed to complete a professional replacement of the entire system! VKMC vehicle applications CAR MAKER MODEL ENGINE ENGINE CODE AUDI A3 (8L1) / A4 (8E2, B6) / A4 Avant (8E5, B6) / A4 (8EC) / A4 Avant (8ED) / A6 (4B, C5) / A6 Avant (4B, C5) A3 (8P1) / A3 Sportback (8PA) / A4 (8EC) / A4 Avant (8ED) / A4 Convertible (8H7, 8HE) 1.9 TDI ASZ, ATD, AVB, AVF, AWX, AXR, BKE, BRB BMM, BPW, BRC FORD GALAXY I 1.9 TDI ANU, AUY, VW19NPD, VW19PPD SEAT SKODA VW ALHAMBRA (7V) / LEON I (1M1) / TOLEDO II (1M2) 1.9 TDI ANU, ASZ, AXR, AUY, BVK, BVK ALTEA (5P1) / ALTEA XL (5P5, 5P8) / LEON II (1P1) / TOLEDO III (5P2) OCTAVIA I (1U2) / OCTAVIA I Combi (1U5) / SUPERB I (3U4) OCTAVIA II (1Z3) / OCTAVIA II Combi (1Z5) / SUPERB I (3U4) / SUPERB II (3T4) BORA (1J2) / BORA Estate (1J6) / GOLF IV (1J1) / GOLF IV VARIANT (1J5) / NEW BEETLE (9C1, 1C1) / Convertible (1Y7) / PASSAT (3B3) / Variant (3B6) / SHARAN (7M) CADDY III (2K, 2C) / GOLF V (1K1) / GOLF V Variant (1K5) / GOLF PLUS (5M1, 521) / EOS (1F7) / PASSAT (3B3) / Variant (3B6) / TOURAN (1T1, 1T2, 1T3) / PASSAT (3C2) / Variant (3C5) / SHARAN (7M) 1.9 TDI 1.9 TDI BMM, BRT ASZ, ATD, AVB, AVF, AWX, AXR, BPZ, BSV BMM, BMP, BSS, BWW ANU, ASZ, ATD, AUY, AVB, AVF, AWX, AXR, BEW, BSW, BVK BGW, BHW, BMM, BMP, BRT, BVH Install confidence

2 Timing belt replacement guidelines TB01142 VKM VKM VKPC Removal of the timing system 1. Safely prepare the vehicle and engine as set out in the vehicle manufacturers guidelines and drain the cooling system. Note: Follow all of the vehicle manufacturing guidelines set out for the preparation of the engine, while replacing the above components! Install confidence In this bulletin the front of the vehicle has been removed to provide detailed photographs and easier access to the system. This is not a necessary step in order to replace the timing system.

3 2. Disconnect the battery and then remove the viscous fan coupling. 3. Using a 19 mm spanner, carefully reverse the tension on the auxiliary drive tensioner and drive belt. Remove the belt and the old tensioner. NEVER reuse an old drive belt! 4. Remove the upper timing cover, crankshaft pulley and the lower cover, as stated in the vehicle manufacturers guidelines. SEE: SKF Pole Position bulletin #8 (VKMA ) for more detailed information on the removal and replacement of the auxiliary drive system, including the freewheel alternator pulley! 5. Turn the crankshaft to TDC on No. 1 cylinder. Check that the marks are aligned at 4Z with the notch on the camshaft. Ensuring that the timing marks are aligned, insert camshaft and crankshaft locking tools (as shown here).

4 6. Loosen the nut on the tensioner roller and turn the adjustment dial anti-clockwise. Slacken the camshaft sprocket bolts (x3) and remove the idler. 7. Remove the belt and the tensioner. Remove the water pump, then thoroughly flush and clean the cooling system. Note: Any old coolant, calcium, rust, metal particles and dirt left in the cooling system will seriously damage the new ceramic seal in the water pump during the bedding in period. Ensure that the whole engine system and radiators are flushed with clean water before reassembly! Refitting the timing system 1. Detailed specific fitting instructions for this timing system application are provided in this kit. 2. Fit the O ring to the new VKPC water pump and install in the engine block. NO SEALING PASTE is required! Torque to 15 NM.

5 3. Ensure that the 3 retaining bolts on the camshaft sprocket are centred in the holes. 4. Check that the retaining pin is correctly fitted in the tensioner. 5. Install new VKM tensioner. Check that tensioner positioning pin is located correctly. 6. Turn the adjustment dial on the tensioner, as far as it will go in a clockwise direction. Finger tighten the retaining nut. 7. Fit the new TB01142 timing belt around the system in the following order: camshaft, tensioner, crankshaft, water pump. Then fit the new VKM idler.

6 8. Torque the idler to 20 Nm. 9. Loosen the tensioner retaining nut. Rotate the tensioner in an anti-clockwise direction, until the retaining pin can be removed. 10. Once the retaining pin has been removed, rotate the tensioner in a clockwise direction, until the pointer is aligned in the centre of the backing plate slot. Torque the tensioner nut to 20 Nm + an angular tightening of 45 Degrees, whilst also ensuring the correct setting of the pointer in the backing plate slot. 11. Torque the 3 camshaft retaining bolts to 25 Nm. 12. Remove locking tools and rotate the engine in a clockwise direction twice. Reset the timing and insert all timing locking tools. Check that the pointer is still aligned with the backing plate notch. 13. Refit the timing covers, refit the crankshaft pulley and torque to 10 Nm plus an angular tightening of 90 degrees. Re-fill the cooling system with the correct, manufacturer approved coolant, ensuring that the cooling system is bled following vehicle manufacturer instructions. For more detailed information, refer to the specific fitting instructions inside the VKMC kit. SKF is a registered trademark of the SKF Group. SKF Group 2011 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein. PUB 80/P EN 2011 Printed on environmentally friendly paper.