Removal and Replacement

Toothed drive belt, removing and installing

(Adjusting valve timing)

See Caution! and Notes under Installation

Special tools, testers and auxiliary items
^ Ribbed belt installation tool 3299
^ Pin wrench Matra V159
^ Torque wrench VAG 1331(5-50 Nm)


Removing

- Remove ribbed drive belt.

- Remove tensioner for ribbed belt.

- Remove crankshaft vibration damper and pulley.

- Remove coolant pump pulley.

- Remove upper and lower parts of drive belt guard.

- Mark running direction on toothed drive belt.

- Loosen tensioner and remove toothed belt.


Installing

Note:
^ For repairs that require the toothed belt to be removed, carry out the toothed belt adjustment as follows.





- Align marking on camshaft sprocket with marking on drive belt guard.

CAUTION!
^ Before turning the camshaft, make sure that the pistons are NOT at Top Dead Center (TDC). With the belt removed, there is danger of damage from valve and piston interference.

- Install drive belt on crankshaft drive belt sprocket and on intermediate shaft drive belt sprocket (note running direction when re-installing a used belt.)

Note:
^ Disregard marking on intermediate shaft drive belt sprocket.

- Install lower drive belt guard.

- Install coolant pump pulley.

- Install crankshaft vibration damper and pulley (note installation position, holes are offset).

- Turn crankshaft to place Cyl. 1 at TDC.


Engine installed:





- Align flywheel -A- or drive plate -B-marks as shown (arrows) to set crankshaft to Cyl. 1 TDC.

Engine removed:





- Turn crankshaft vibration damper to align notch with timing mark (arrow) and set crankshaft to Cyl. 1 TDC.





- Turn intermediate shaft drive belt sprocket with toothed belt (in direction indicated by arrows) until distributor rotor aligns with Cyl. 1 marking on distributor housing.

Drive belt slips over teeth of crankshaft drive belt sprocket.

- Install toothed drive belt on tensioner roller and camshaft drive belt sprocket.

Note:
^ To make drive belt installation easier, loosen tensioner roller lock nut by approximately one thread.





Marking for Cyl. 1 on distributor housing





- Increase tension on toothed belt by turning tensioner pulley with pin wrench (e.g. Matra Vi 59) in direction of arrow.

^ It must be just possible to twist the belt by 900 with the thumb and forefinger half-way between the camshaft and intermediate shaft sprockets.

- Tighten lock nut on belt tensioner.
Tightening torque: 45 Nm (33 ft lb)

- Turn crankshaft though two complete revolutions and recheck adjustment.

- Check alignment of ignition distributor rotor with markings on distributor housing.

- Install upper drive belt guard.

- Install tensioner for ribbed belt.
Tightening torque: 20 Nm (15 ft lb)

- Install ribbed drive belt.