Issue 9 · 2011

Timing belt kit including water pump

VKMC 01250-1

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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.

VKMC 01250-1 vehicle applicationsCAR 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) 1.9 TDI ASZ, ATD, AVB, AVF, AWX, AXR,

BKE, BRB

A3 (8P1) / A3 Sportback (8PA) / A4 (8EC) / A4 Avant (8ED) / A4 Convertible (8H7, 8HE) 2.0 TDI BMM, BPW, BRC

FORD GALAXY I 1.9 TDI ANU, AUY, VW19NPD, VW19PPD

SEATALHAMBRA (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) 2.0 TDI BMM, BRT

SKODAOCTAVIA I (1U2) / OCTAVIA I Combi (1U5) / SUPERB I (3U4) 1.9 TDI ASZ, ATD, AVB, AVF, AWX,

AXR, BPZ, BSV

OCTAVIA II (1Z3) / OCTAVIA II Combi (1Z5) / SUPERB I (3U4) / SUPERB II (3T4) 2.0 TDI BMM, BMP, BSS, BWW

VW

BORA (1J2) / BORA Estate (1J6) / GOLF IV (1J1) / GOLF IV VARIANT (1J5) / NEW BEETLE (9C1, 1C1) / Convertible (1Y7) / PASSAT (3B3) / Variant (3B6) / SHARAN (7M)

1.9 TDIANU, ASZ, ATD, AUY, AVB, AVF, AWX, AXR, BEW, BSW, BVK

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)

2.0 TDI

BGW, BHW, BMM, BMP,BRT, BVH

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.

The VKMC 01250-1 kit has all of the components needed to complete a professional replacement of the entire system!

FORD VAG

Timing belt replacement guidelines

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Note: Follow all of the vehicle manufacturing guidelines set out for the preparation of the engine, while replacing the above components!

VKM 11250 VKM 21147 VKPC 81626TB01142

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.

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.

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.

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).

SEE: SKF Pole Position bulletin #8 (VKMA 31020-1) for more detailed information on the removal and replacement of the auxiliary drive system, including the freewheel alternator pulley!

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!

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.

2. Fit the ‘O’ ring to the new VKPC 81626 water pump and install in the engine block. NO SEALING PASTE is required!

Torque to 15 NM.

Refitting the timing system

1. Detailed specific fitting instructions for this timing system application are provided in this kit.

5. Install new VKM 11250 tensioner.

Check that tensioner positioning pin is located correctly.

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.

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 21147 idler.

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.

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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.

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 01250-1 kit.

11. Torque the 3 camshaft retaining bolts to 25 Nm.