2003 Volkswagen Golf GLS
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1 VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE On models, the manufacturer suggests the belt AND tensioner be replaced at 60,000 mile intervals. On 2000 models, the manufacturer suggests the belt AND tensioner be replaced at 40,000 mile intervals. On 2001 models equipped with automatic transaxles, the manufacturer suggests the belt be replaced at 40,000 mile intervals. On 2001 models equipped with manual transaxles, the manufacturer suggests the belt be replaced at 60,000 mile intervals. On 2002 models, the manufacturer suggests the belt be replaced at 80,000 mile intervals. On 2003 models, the manufacturer suggests the belt be replaced at 100,000 mile intervals. On all models, the manufacturer suggests the tensioner be replaced at 105,000 mile intervals. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. REMOVAL & INSTALLATION TIMING BELT Removal (Golf & Jetta) NOTE: Timing belt installation procedure requires using a factory scan tester (VAG 1551/1552) to adjust injection pump timing. 1. Remove upper engine cover. Remove right sound damper cover. Rotate serpentine belt tensioner clockwise to relieve belt tension, and remove serpentine belt. Remove serpentine belt tensioner. 2. Remove brake booster vacuum pump. Remove upper timing belt cover. Remove engine valve cover using care not to damage gasket. Remove tube between charge air cooler and intake manifold. Right headlight may need to be removed to remove this tube. 3. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. TDC mark can be viewed through access hole in engine-to-transmission mating flange. See Fig Lock camshaft in place with Camshaft Setting Bar (3418) installed on rear of camshaft. See Fig. 2. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. 5. Divide this dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of same dimension between other end of bar and cylinder head. 6. Lock injection pump in place using Lock Pin (3359). See Fig CAUTION: DO NOT loosen diesel injection pump center hub nut. This will alter injection pump basic setting. Loosen, but do not remove, the 3 diesel injection pump sprocket mounting bolts. Replace these bolts with NEW bolts during installation. Support engine weight from above or below with floor jack. Remove coolant reservoir bottle and power steering reservoir (both with hoses attached) and set aside. 2 января 2005 г. 0:16:13 Page Mitchell Repair Information Company, LLC.
2 8. Remove engine mount from timing belt end of engine. Remove 4 crankshaft pulley bolts and remove crankshaft pulley (it is not necessary to remove center bolt). Remove middle and lower timing belt covers. Remove engine mount bracket. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Move timing belt tensioner, and remove timing belt. CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. 2 января 2005 г. 0:16:13 Page Mitchell Repair Information Company, LLC.
3 2 января 2005 г. 0:16:13 Page Mitchell Repair Information Company, LLC.
4 Fig. 1: Locating TDC Mark on Flywheel/Flexplate Fig. 2: Locking Camshaft With Setting Bar 2 января 2005 г. 0:16:13 Page Mitchell Repair Information Company, LLC.
5 Fig. 3: Locking Diesel Fuel Injection Pump Sprocket Removal (New Beetle) 1. Remove tube between charge air cooler and air intake pipe. Disconnect and plug fuel supply and return lines at fuel filter. Remove fuel filter from bracket. 2. Remove upper timing belt cover. Remove valve cover. Remove brake booster vacuum pump. Remove pipe between charge air cooler and turbocharger. 3. Remove right side insulation tray. Rotate tensioner clockwise, and remove serpentine drive belt. If reusing serpentine drive belt, mark belt with direction of rotation. 4. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. TDC mark can be viewed through access hole in engine-to-transmission mating flange. See Fig Lock camshaft in place with Camshaft Setting Bar (3418) installed on rear of camshaft. See Fig. 2. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. 6. Divide this dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of same dimension between other end of bar and cylinder head. 2 января 2005 г. 0:16:13 Page Mitchell Repair Information Company, LLC.
6 7. Lock the injection pump in place using Lock Pin (3359). See Fig CAUTION: DO NOT loosen diesel injection pump center hub nut. This will alter injection pump basic setting. NOTE: The 3 diesel injection pump bolts are torque-to-yield type. Manufacturer recommends replacing bolts during final assembly. 9. Loosen, but do not remove, the 3 diesel injection pump sprocket mounting bolts. Manufacturer recommends replacing these torque-to-yield bolts during final assembly. Support engine weight from above or below with floor jack. NOTE: On New Beetle, engine mount bolts are torque-to-yield type. Manufacturer recommends replacing bolts if they are loosened or removed. Remove engine mount from timing belt end of engine. Remove 4 crankshaft pulley bolts, and remove crankshaft pulley (it is not necessary to remove center bolt). Remove timing belt covers. 10. If reusing old timing belt, mark belt with arrow to indication original direction of rotation. Loosen, but do not remove, timing belt tensioner nut, and remove timing belt. CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. Installation (All Models) NOTE: Timing belt installation procedure requires using a factory scan tester (VAG 1551/1552) to adjust injection pump timing. 1. Ensure cylinder No. 1 is at TDC. Check reference mark on flywheel and bellhousing. 2. CAUTION: Use Spanner Wrench (3036) to hold camshaft sprocket while loosening center bolt. DO NOT use camshaft setting bar to hold camshaft sprocket. Holding camshaft stationary, loosen camshaft sprocket bolt 1/2 turn. See Fig. 4. On New Beetle, place drift punch through rear timing belt cover and LIGHTLY tap camshaft sprocket loose from tapered end of camshaft. On Golf and Jetta, use a Two Arm Puller (T40001) to remove sprocket. Remove camshaft sprocket. 3. Install timing belt onto crankshaft sprocket, idler pulley, water pump, injection pump sprocket, and tensioner pulley. If installing old belt, note direction of rotation mark. 4. Install camshaft sprocket together with timing belt. Install camshaft sprocket bolt finger tight. Camshaft sprocket should still be free to turn. 5. On Golf and Jetta with automatic transaxle, use an Allen wrench to turn timing belt tensioner clockwise until notch and pointer align. See Fig. 5. If tensioner is turned too far and correct tension is exceeded, tension must be fully released, and then readjusted. Tighten center lock nut on tensioner pulley to specification. See TORQUE SPECIFICATIONS. 6. On Golf and Jetta with manual transaxle and New Beetle, install Tension Pin Wrench (MATRA 2 января 2005 г. 0:16:13 Page Mitchell Repair Information Company, LLC.
7 V159) on timing belt tensioner pulley. See Fig. 6. Turn wrench clockwise until notch and raised mark are aligned. Tighten tensioner pulley center nut to specification. See TORQUE SPECIFICATIONS. 7. On all models, ensure tensioner is correctly installed in rear timing belt cover. See Fig. 7. Ensure TDC marks on flywheel are still aligned. Tighten camshaft sprocket center bolt to specification. See TORQUE SPECIFICATIONS. 8. Install NEW torque-to-yield mounting bolts in diesel injection pump sprocket. Tighten injection pump bolts to 15 ft. lbs. (20 N.m). Before final tightening injection pump mounting bolts, perform start of injection procedure (dynamic timing) using factory scan tester (VAG 1551/1552). Final tighten injection pump sprocket mounting bolts about 90 degrees. 9. Remove camshaft setting bar from rear of camshaft. Remove lock pin from injection pump. 10. Rotate crankshaft 2 complete revolutions. Place crankshaft at TDC and ensure belt timing is correct. Ensure timing belt tensioner pulley marks are still aligned. 11. Install engine mount bracket to engine block. Install timing belt covers. Install crankshaft pulley. 12. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS. Check fuel lines for leaks. Adjust drive belts to proper tension. On New Beetle, check injection pump start of delivery with scan tool. 2 января 2005 г. 0:16:14 Page Mitchell Repair Information Company, LLC.
8 Fig. 4: Securing Camshaft Sprocket 2 января 2005 г. 0:16:14 Page Mitchell Repair Information Company, LLC.
9 Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta With Automatic Transaxle) 2 января 2005 г. 0:16:14 Page Mitchell Repair Information Company, LLC.
10 Fig. 6: Adjusting Timing Belt Tension (Golf & Jetta With Manual Transaxle, & New Beetle) 2 января 2005 г. 0:16:14 Page Mitchell Repair Information Company, LLC.
11 Fig. 7: Installing Timing Belt Tensioner TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS (GOLF & JETTA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 33 (45) Crankshaft Pulley Bolt 18 (25) Diesel Injection Pump Sprocket Bolts (1) 15 (20) + 90 Degrees Engine Mount Bracket-To-Engine Bolt 33 (45) Idler Pulley Bolt 15 (20) Serpentine Drive Belt Tensioner 18 (25) Timing Belt Tensioner Pulley Nut 15 (20) Vacuum Pump Bolt 15 (20) Water Pump Bolts 16 (22) INCH. Lbs. (N.m) Timing Belt Cover Bolt 89 (10) Valve Cover Nut 89 (10) (1) Replace with new torque-to-yield bolts on installation. 2 января 2005 г. 0:16:14 Page Mitchell Repair Information Company, LLC.
12 TORQUE SPECIFICATIONS (NEW BEETLE) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 33 (45) Crankshaft Pulley Bolt 18 (25) Diesel Injection Pump Sprocket Bolts (1) 15 (20 ) + 90 Degrees Engine Mount Bracket-To-Engine Bolt (1) 30 (40) + 90 Degrees Engine Mount-To-Bracket Bolt (1) 44 (60) + 90 Degrees Idler Pulley Bolt 15 (20) Timing Belt Tensioner Pulley Nut 15 (20) Water Pump Bolts 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt 89 (10) Valve Cover Nut 89 (10) (1) Replace with new torque-to-yield bolts on installation. 2 января 2005 г. 0:16:14 Page Mitchell Repair Information Company, LLC.
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