Toothed Belt, Removing, Installing and Tensioning
Toothed Belt, Removing, Installing and Tensioning
Special tools, testers and auxiliary items required
• Locking pin (3242)
• Puller (T40001)
• Camshaft locator (T40005)
• Tightener pulley wrench (T40009)
• Securing pin (T40011)
• Reversible ratchet (VAS 5122)
• Torque wrench (V.A.G 1410)
• Torque wrench (V.A.G 1331)
Removing
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.
- Remove noise insulation tray.
- Remove coolant fan with mount --> [ Coolant Fan with Mount ] Coolant Fan with Mount.
- Bring lock carrier into service position: --> Body Exterior 50 Removal and Installation Radiator Support
- Mark ribbed belt and remove it. --> [ Ribbed Belt ] Ribbed Belt
- Remove left and right toothed belt cover.
- Mark running direction of toothed belt using a felt tip marker.
- Set crankshaft to top dead center (TDC). The marking on toothed belt cover - A - must be aligned with notch on belt pulley - B -.
- Check position of camshaft gears. The large holes on securing plates - arrows - must align on inside.
• If the large holes are positioned on the outer side of the toothed belt gears, crankshaft must be turned one rotation further in engine running direction.
- Remove sealing plug from left-side of cylinder block - arrow -. The TDC hole for crankshaft must be visible or felt behind hole for sealing plug.
- Carefully install crankshaft holder (3242) into hole up to stop, and thereby secure crankshaft against turning.
- Remove center toothed belt guard.
- Remove vibration damper.
• The vibration damper is fastened to the crankshaft with 8 bolts.
- First, remove bolt - 1 - from oil filter housing and then remove bolts - 2 - of cover for toothed belt tensioning element.
- Remove cover.
• The toothed belt tensioner is oil-dampened. Therefore it can only be compressed slowly.
• Use locking pin (T40011) to secure tensioning element.
- If necessary, align holes in the housing and tensioning element piston using a pair of needle nose pliers or a thin piece of wire, before tensioning.
- Turn tensioning lever of toothed belt tensioning roller - 1 - in direction of - arrow - using a hex socket wrench.
- When tensioning lever - 2 - pushes toothed belt tensioning element together so that the holes in housing and piston align, secure tensioning element using locking pin (T40011).
- Place camshaft adjustment (T40005) into securing plates of camshafts and loosen bolts approx. 5 turns.
- Remove camshaft locator (T40005) again.
- Now remove camshaft gears from cone using puller (T40001) and claws (T40001/2).
- Loosen tensioning roller - arrow - and remove toothed belt.
Installing and Tensioning
- On used toothed belts, observe marking for direction of rotation.
- Set toothed belt onto toothed belt crankshaft gear - 1 - first, then onto idler roller of the toothed belt tensioner - 2 - and then onto tensioning roller - 3 -. Then, set it onto camshaft gears and coolant pump belt pulley as shown in the illustration.
• Camshaft gears must just be able to be twisted on cone for camshafts.
- Install camshaft adjustment (T40005) onto camshaft gears again.
- Set a 5 mm drill between tensioning lever and piston of tensioning element - arrow -.
- Pretension still loosened tensioning roller using torque wrench (V.A.G 1410) and connected reversible ratchet (VAS 5122) with tensioning roller wrench (T40009) counter-clockwise - arrow - to 4 Nm.
- In this position, tighten bolt - 1 - to 45 Nm.
- Then remove 5 mm drill bit again.
- Turn tensioning lever of toothed belt tensioning roller - 1 - in direction of - arrow - using a hex socket wrench.
- When tensioning lever has compressed the piston in the toothed belt tensioning element - 2 -, pull out locking pin (T40011).
- Turn tensioning lever of toothed belt tensioning roller - 1 - in direction of - arrow - using a hex socket wrench, and place a 7 mm drill bit between housing and tensioning lever.
- Tighten camshaft gears to 55 Nm.
- Remove camshaft locator (T40005) again.
- Remove drill bit, that was inserted between housing and tensioning element.
- Remove crankshaft holder (3242) from hole and install sealing plug - arrow - and tighten to 30 Nm.
- Turn over crankshaft twice in direction of engine rotation and check adjustment dimension - a -: Specified value 5 mm
The rest of assembly is basically a reverse of disassembling sequence.