VW Type A-4 Timing Belt Replacement Procedure PDF Installation Instructions

Finally the procedure we have all been waiting for: the “A4 Timing Belt Procedure”, including the automatic and manual transmission differences. Some people have argued till they are blue in the face that “mark and pray” was the easiest way to change one of these belt, and it has been proven that this belt can be changed in under 2 hours using the full factory method as demonstrated here in this thread. The procedure utilizes all the factory tools and processes. The reason for going to the extreme of utilizing all the tools is the elimination of all possibilities of making a $2500.00+ mistake and destroying the head. You do not need many tools to complete this job. What you do need is a thorough understanding of
the procedure and what you are about to accomplish

When changing a timing belt, you are doing more than just replacing an old belt.What you are doing, whether performing a 40K on the auto or 60K on a manual, is inspecting the entire engine area that has been covered up since the engine was new or since the last belt change. The second most important thing this procedure accomplishes is it totally resets ALL timing settings on the engine and restores them back to factory new settings

While on the topic of timing, we need to understand that there are three types of timing involved here:
1.The first and most overlooked type of timing is the cam and crank timing.This keeps the cam spinning in perfect time allowing the engine to produce great low-end power as well as allowing the engine to rev to it’s full redline of 5100 rpm.
2.The second type of timing is “basic” injection timing. I concocted the word “basic” timing because it is used to initially set and assure that the engine will start.This is accomplished by inserting the injection pump lock pin: positioning the pump shaft in relation to cam and crank timing in such a way that injection will occur within the ignition window.
3. Once the cam & crank timing have been set and the Injection pump is positioned, you will need to adjust the injection timing utilizing the Vag-Com®. If you do not have this, then get it before attempting to perform this procedure.
This leads me to my next point: tools. Everybody wants to know where to get them and how much they cost.The simple fact is they are not cheap, but neither is your engine. I use the factory tools that I got sell all the tools you need for the job and they are the same tools the factory used to assemble your beloved engine so again it’s your engine and your money.

The VW Factory tools you are going to need are:
1.) 3036 camshaft holding bar
2.) 3418 camshaft setting bar
3.) 2587 2 pin spanner wrench (don’t use a bicycle wrench this one costs the same!)
4.) 3359 Injection pump lock pin
5.) T40001 puller set
Specialty tools you are going to need from Sears:
1.) 41831 serpentine belt tensioner tool
2.) 44360 11mm&10mm 45 degree offset wrench
3.) 5mm 3/8 drive allen socket
4.) 6mm 3/8 drive allen socket
Other tools and “stuff”
1.) T25 Torx® specialty tool from AutoZone
2.) Flat band clamp pliers
3.) Block of wood, a 2×4 6″ long will work great
4.) Jack stands (strong enough to support your car
5.) Hydraulic floor jack
6.) You will also need a set of metric 1/4”, 3/8” and 1/2″ drive sockets and extensions