tb042 - Vag 2.5-v6 Tdi

VAG 2.5 V6 TDI – Timing Belt set-up.
GATES REFERENCE : 5520XS, K035520XS, K045520XS, 5531XS and

kits, 5557XS, K015557XS, K025557XS,
T41095, T43029, T43036.
MAKE : AUDI / SKODA / VOLKSWAGEN
MODEL : A4, A6, A8, Superb, Passat
ENGINE : 2.5 V6 TDI
# 042 ENGINE CODE : AFB, AKE, AKN, AYM, BAU, BCZ, BDG, BDH,
31/01/2011 BFC.
Through our field visits we have learned of several possible issues with
these engines. In a lot of cases these issues will lead to engine failure.
Possible problems:
1) Camshaft wear on the early models (up to 2003): there are potential
issues with insufficient lubrication of the camshafts. This will lead to
power loss, insufficient combustion (exhaust smokes), possible
shearing off of the (normal) rocker arms (Fig. 1); resulting in camshaft
wear (Fig. 2), blockage and belt rupture. Later models equipped with
“roller” rocking arms do not have this issue anymore.
2) Although the Timing Belt is tensioned by means of a hydraulic
tensioner element, many errors are made during the tensioner
setting, leading to premature belt failure.
3) In some cases a rough running vacuum pump (hard points) will put
extra wear on the belt, possibly leading to premature failure.
Fig. 1 Fig. 2
Recommendations
It is vital that the correct installation tools (to be found in GAT4450) are used
in order to fit the belts correctly. To prevent premature belt failure, always
follow the manufacturers’ recommended fitting procedure.
1) Turn the engine clockwise until the ‘OT’ marking on the camshaft is
centered through the oil filling hole (oil filler cap removed) (Fig 3).
Fig. 3 Fig. 4
Technical Bulletin 042
Copyright © 2011 Gates Corporation Page 1 of 4

2) Remove the TDC cap from the engine block and put in the crankshaft
locking pin (GAT4401); which is used to retain the crankshaft at TDC
position. The locking pin has to be screwed in via a threaded hole in
the crankcase (Fig.4).
3) By removing both camshaft cover (cap) and the vacuum pump at the
back of the cylinder heads, you will be able to put the camshaft setting
plates (GAT4451) in the slots in the rear of each camshaft (Fig. 5).
They are supplied with chains which are attached to a suitable engine
# 042 part to prevent them from falling.
31/01/2011
NOTE: Setting plates cannot be used to hold camshafts in place
when releasing sprocket bolts. They are only for holding timing
position!
Fig. 5
4) Remove the 4 bolts from the injection pump (IP) vibration damper, and
the damper. Do not undo the central bolt!!!
5) Insert the IP locking pin (GAT4440V2), slacken tensioner nut, remove
IP belt, remove ventilator support and tensioner, remove outer
camshaft sprocket.
6) Rotate tensioner clockwise till 2 mm pin (GAT 4360T1) can be fully
inserted in hydraulic element (Fig. 12).
7) While holding camshaft sprockets, slacken bolts and make sprockets
loose on cones (GAT4848), remove LH sprocket.
8) Check engine still at TDC position.
9) Hand tighten bolt of RH camshaft sprocket.
10) Remove belt, tensioner (pulley, lever, hydraulic element) and idler.
11) Install new idler. ATTENTION!!! The idler now has a countersunk
hole (Fig 6), needing a shorter bolt (supplied in the kit). Failure to use
the correct bolt will lead to incorrect clamping, with a sheared bolt as a
result (Fig. 7)
Fig. 6 Fig.7

12) Install rest of tensioner system. ATTENTION!!!
Particular attention needs to be taken in relation to the position of the
lever and pin located behind the tensioner roller:
Fig 8 shows the only possible correct lever/pin contact.
# 042
31/01/2011 √
Fig. 8 Fig. 9
Correct Incorrect
Do not forget (1) washer behind lever and tensioner pulley!!
Any incorrect contact of the lever arm with the pin on the tensioner, or
lack of washer, will cause serious damage to the system; with belt
failure as a result (Fig.10).
Fig 10 Fig 11
Fixing bolt 8 mm Allen key
13) Install new belt in following order: crankshaft, right hand camshaft,
tensioner, idler, water pump.
14) Put left hand camshaft sprocket into belt, install sprocket and belt on
camshaft.
15) Install camshaft bolts finger tight
16) Turn the tensioner pulley slightly clockwise using an Allen key in the
hexagonal slot (Fig 11). The lever comes to a stop on the tension
piston rod (Fig. 12). Remove the hydraulic tensioner retaining pin.
Fig 12
Retaining pin

17) Turn the tensioner pulley anti-clockwise, against the force of the
damper, using a dynamometric wrench into the Allen key hole and
applying a load of 15Nm (CRITICAL) Because of the oil pressure in
the hydraulic element, this will make the tensioner pulley move out of
the lever (avoiding later contact (Fig. 10)) and tension the belt.
18) While you keep the pivot deflection lever in this correct position,
torque the tensioner pulley fixing bolt (Fig 11) to 42 Nm
Now check the position of the hydraulic piston: Fig 13 shows the
# 042 correct hydraulic piston position, Fig. 14 the incorrect position.
31/01/2011
19) Torque the camshaft sprocket bolts to 75 Nm, while holding them in
place with GAT4394.
Fig 13 Fig 14
20) Verify engine is still at TDC, install new IP tensioner (nut hand tight)
and ventilator support.
21) Install outer camshaft sprocket, bolts hand tight in centre of slotted
holes. Install new belt.
22) Use GAT4452 (Fig. 15) over tensioner nut, turn tensioner with Allen
key anti-clockwise till pointer aligns, tighten nut to 37 Nm with
GAT4452 while holding tensioner in correct position with Allen key!!!
(Fig. 16). Remark: it is possible to tension the belt by turning the
tensioner clockwise, BUT this will lead to engine damage.
23) Tighten the 3 bolts to 22 Nm while holding camshaft in place with
GAT4394.
24) Remove locking tools, turn engine 2 revolutions to TDC, insert locking
tools, check pointer position (correct if needed); remove locking tools,
fit IP vibration damper, torque bolts to 22 Nm, fit new camshaft cap.
Fig 15 Fig. 16
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VAG 2.5 V6 TDI – Timing Belt set-up.

GATES REFERENCE : 5520XS, K035520XS, K045520XS, 5531XS and

Technical Bulletin 042

Copyright © 2011 Gates Corporation Page 1 of 4

Copyright © 2011 Gates Corporation Page 2 of 4

Copyright © 2011 Gates Corporation Page 3 of 4

Visit our web catalogue : www.gatesautocat.com

Copyright © 2011 Gates Corporation Page 4 of 4

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