REPXPERT Alistair Mason replaces the timing belt and coolant pump on a 2015 Volkswagen Crafter fitted with a 2.0 TDI common rail engine.
The recommended service schedule for the timing belt is 80,000 miles or 4 years (which ever comes sooner), with over 55,000 Volkswagen Crafter’s currently on the UK roads today, this is a great repair for any independent workshop, the recommended book time for this repair is 3.30 hours and with few special tools required and a little guidance, this could easily be a profitable job.
Full workshop instructions and technical bulletins are available through Schaeffler’s REPXPERT workshop information system.
When replacing the timing belt, it is strongly advised to follow Schaeffler’s 4T guidelines,
• Temperature – Ensure the engine is at an ambient temperature.
• Tools – Always use the correct tools and engine timing tools.
• Torque – Always use a calibrated torque wrench and torque bolts to the manufactures recommendations.
• Tension – The belt tension must be set correctly.
The following workshop equipment was used for this repair,
• Engine timing/locking tools.
• Calibrated torque wrench.
• Coolant draining collection system.
For this scheduled repair, the majority of the work is carried out from the top of the engine bay, so a vehicle lift is not essential. With the engine at ambient temperature, open the bonnet and remove the air filter assembly (figure 1) by disconnecting the two electrical multi-plugs, unclip the oil filler neck and jump start point, disconnect the two air intake pipes, lift the front of the filter assembly up to withdraw it from the rubber grommets and then slide it forwards to remove from the rear mounting points, once removed, stow in a safe area, this now gives a greater access to the timing belt area. Now remove the viscous fan, if this proves to be too tight to remove, remove the three bolts from the mounting bracket and stow the fan assembly carefully in the radiator cowling. Before the auxiliary drive belt is removed, slacken the four spline bolts that retain the bottom pulley (figure 2), once slackened, turn the auxiliary drive belt tensioner in a clockwise direction, with the tension released, remove the auxiliary drive belt and then remove the bottom pulley, at this point, check the auxiliary belt tensioner and over-running alternator pulley for serviceable and correct operation, replace if required.
Now remove the timing belt covers, unclip the upper cover and remove, then remove the five bolts from the lower cover and remove, using a 19mm twelve point socket on the crankshaft bolt, rotate the engine in a clockwise direction until the locking pin can be inserted into the camshaft pulley (figure 3), check the crankshaft pulley aligns and lock in with the special tool (figure 4), finally the pulley can now be locked for the high pressure fuel pump (figure 5). Slacken the three retaining bolts for the camshaft pulley and the three retaining bolts for the high pressure fuel pump pulley, slacken the timing belt tensioner nut and rotate the tensioner eccentric in an anti-clockwise direction, with the tension removed, the timing belt can be removed from the engine.
These days we need to bear in mind that the use of stretch bolts and one time use, self-locking fixings are becoming more popular, the INA timing belt kit contains all fixings that need replacing for this repair.
Starting at the top, replace the three bolts that retain the camshaft pulley, replace the top idler pulley and bolt, replace the high pressure fuel pump pulley bolts and then remove the large deflection pulley. With this pulley removed, there is good access to replace the coolant pump, if possible drain the coolant into a coolant drainer/collection system, then remove the three retaining bolts from the coolant pump and remove the coolant pump. Ensure the coolant pump location area and timing belt area is clean and dry, put a light smear of silicone based grease on the new coolant pump seal and the insert into the engine block, once bolted into place, torque to the manufactures specification and then fit the new deflection pulley and bolt.
In the INA timing belt kit there are two new studs which are strongly recommended to be replaced as they have the potential to stretch. Replace the stud for the tensioner and also for the lower deflection/idler pulley, this can be done by using a stud extractor or locking two nuts together (figure 6), when fitting the new studs, ensure they are torqued to the manufactures recommendation, once torqued, fit the new tensioner ensuring the locating tab locates and the fit the lower deflection pulley/idler, torque bolts as required leaving the cam and high pressure fuel pump pulley bolts and tensioner nut free so the pulleys and tensioner can rotate, move both pulleys in the clockwise direction until they are against their stops.
Fit the new timing belt, starting at the crankshaft and working in a clockwise direction finishing off by sliding the belt onto the large deflection pulley. Once the belt is positioned correctly, tension the tensioner by turning the eccentric on the tensioner in a clockwise direction until the two pointers align (figure 7), once aligned, torque the nut to the recommended torque and then the cam and pump pulleys should be in a central position on their bolt holes, if not, adjust the belt position on the pulley and re-tension, once confirmed, torque the cam and pump pulley bolts to the recommended torque.
Remove the locking pins from the cam and high pressure fuel pump pulleys and remove the locking tool from the crank pulley (figure 8), rotate the engine in the direction of rotation two complete revolutions and re-insert the locking tools, this confirms the timing is correct, also check the pointer on the tensioner is still in the correct position. Confirm all nuts/bolts are torqued correctly and then refit all components in reverse order of removal. When fitting the viscous fan assembly, install one bolt and then lever the bracket into position so the other two bolts can be installed. Always use new coolant when re-filling the cooling system ensuring it is the correct grade. In this repair we replaced the auxiliary drive belt as it is recommended when replacing the timing belt.
Run the vehicle topping up the coolant as required, once the level has stabilised, carry out an extended road test to ensure the cooling system has bleed through.
Information on Schaeffler products, fitting instructions, repair times and much more can be found on the REPXPERT garage portal www.repxpert.co.uk, or calling the Schaeffler technical hotline on 01432 264264