Toothed Belt, Removing and Installing, Tensioning
Toothed belt, removing and installing, tensioning
Special tools, testers and auxiliary items required
^ Counter-holder tool 3036
^ Crankshaft holder 3242
^ Camshaft locating tool 3391
^ Puller T40001
^ Pin T40011
^ Torque wrench V.A.G 1331
Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1332
Removing
CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
^ Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
- Bring lock carrier into service position. [1][2]Procedures
- Remove ribbed belt and tensioner.
Vehicles with secondary air injection system
- Disconnect hose - arrow - from connecting pipe for Secondary Air Injection (AIR).
Continued for all vehicles
- Remove viscous fan clutch.
- Remove upper part of toothed belt guard at right and left.
- Set crankshaft to TDC cylinder 3. Marking on toothed belt guard - A - must align with notch on belt pulley - B -.
- Check position of camshaft gears. Large holes on securing plates - arrows - must align on inside.
Note: If large holes stand on outer side of toothed belt gears, crankshaft must be turned one more rotation.
- Remove sealing plug from left side of cylinder block. TDC hole for crankshaft must be visible or felt behind hole for sealing plug.
- Screw crankshaft holder 3242 into hole so that crankshaft is prevented from turning.
- Remove center toothed belt guard.
- Remove vibration damper/belt pulley (8 bolts).
- Remove bracket for viscous fan clutch and toothed belt guard belt pulley - arrows -.
- Loosen bolts of both camshaft gears, counterhold using retainer 3036.
Note: The bolts remain loose but threaded in place.
- Remove left and right camshaft gears from cone using puller T40001 with claws T40001/2.
- Turn toothed belt tensioning roller - 1 - in direction of arrow using a hex socket wrench. When tensioning lever - 2 - pushes toothed belt tensioning element - 3 - together so that holes in housing and lifter align, secure tensioning element using locking pin T40011.
- If necessary, align lifter using needle nose pliers or thin wire.
Note:
^ The toothed belt tensioner is oil-dampened. Therefore it can only be compressed slowly.
^ Use locking pin T40011 to secure tensioning element.
- Mark direction of rotation of toothed belt.
- Remove toothed belt.
Installing
- Tighten securing bolts for camshaft gears by hand.
Note: Camshaft gears must just be able to be twisted on cone for camshafts.
- Route toothed belt as shown. For a used toothed belt, running direction must be observed.
- Place camshaft locating tool 3391 into securing plates of both camshafts.
Tensioning
- Turn tensioning roller - 1 - using a hex socket wrench to right far enough until locking pin T40011 can be pulled out of tensioning element - 3 -.
- Place torque wrench V.A.G 1331 onto socket head of tension roller - 1 - and put tension on roller - 1 - with 15 Nm in tensioning direction.
- After toothed belt is tensioned, tighten camshaft gears to 55 Nm.
- Install fan bracket for viscous fan clutch and toothed belt guard belt pulley.
- Install vibration damper to belt pulley with 8 bolts. Tightening torque: 25 Nm.
Note: Locating points on vibration damper/belt pulley - arrows - must be aligned with locating tabs on toothed belt gear.
- Remove crankshaft holder 3242.
The rest of the assembly is basically a reverse of the disassembly sequence.