Toothed Belt, Removing and Installing

Special tools and equipment:
- Spring pin from 2024 A
- Pin wrench 3212
- Open end wrench 3312
- Wrench 3078 (22 mm)
- Clamping bolt 3242
- Camshaft bar T40005
- Puller T40001
- Torque wrench V.A.G 1410
- Socket attachment VAS 5122
- Tensioning roller key T40009
- Pin T40011

Removing





- Remove cover -1-.
- Remove air intake hose for air cleaner -2- .





- Remove engine cover -arrows-.
- Remove cylinder head covers -1- and -2-.
- Disengage spring clips at toothed belt cover.
- Remove toothed belt cover.





- Remove noise insulation -arrows-.
- Removing and installing ribbed belt. Service and Repair
- Remove electric fan.
- Remove ribbed belt pulley for viscous fan.





- Turn crankshaft to TDC by hand. Markings -A- and -B- must be aligned.





- Check position of camshafts: the larger holes (arrow)in the securing plates on the camshaft sprockets must be in line with each other and facing inward. If not, turn crankshaft one revolution.





- Remove sealing plug (arrow) from left side of cylinder block.
- TDC drilling in crankshaft must be behind sealing plug hole (feel to check).





- Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.





- Remove tensioner for ribbed belt.
- Remove vibration dampener.





- Remove bracket for viscous fan (arrow).

Notes:
- Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when reinstalled.
- The toothed belt tensioning element is oil damped. To compress tensioning element apply constant pressure (compresses slowly).





- Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until tensioning element-2- is compressed far enough to insert pin T40011 in the drilling and in the plunger.
- With T40011 inserted release toothed belt tensioning lever.





- Install camshaft bar T40005 onto securing plates of the two camshafts.
- Loosen the two camshaft bolts and unscrew approximately 5 turns.
- Remove camshaft bar T40005.





- Pull off both camshaft sprockets using puller T40001.





- Loosen toothed belt tensioning roller (arrow).
- Remove toothed belt together with camshaft sprocket for cylinder bank 1-4.

Installing





- First install toothed belt on crankshaft sprocket, idler wheel for tensioner, tensioning roller, camshaft sprocket for cylinder bank 5-8, coolant pump and dampener wheel.
- Then take camshaft sprocket for cylinder bank 1-4, install toothed belt and bolt sprocket onto camshaft.
- Lightly secure both camshaft sprockets with securing plates by tightening hand tight.

Note: The camshaft sprockets must be tight enough on the camshaft tapers to be turned but not to be moveable axially.

- Attach camshaft bar T40005.





- Insert a 5 mm drill bit between tensioner and hydraulic piston (arrow).





- Tension toothed belt initially to 4 Nm (35 inch lbs.) using tensioning key T40009 and torque wrench V.A.G 1410 with socket attachment VAS 5122 by turning in direction of arrow. Then tighten eccentric wheel to 22 Nm (16 ft. lbs.).
- Remove 5 mm drill bit.





- Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until spring pin can be removed.





- Using 8 mm Allen key, turn toothed belt tensioning lever in direction of arrow until 7 mm drill bit can be inserted between toothed belt tensioning lever and hydraulic tensioning element.
- Tighten bolts on camshaft sprockets.

Note: Use camshaft bar T40005 to prevent camshafts from turning.

- Remove camshaft bar T40005.
- Remove 7 mm drill bit.
- Remove crankshaft clamping bolt 3242 and install sealing plug in hole.
- Turn crankshaft 2 revolutions.





- Measure distance -a- between toothed belt tensioning lever and hydraulic tensioning element.
Dimension a = 5 mm.
- If the dimension is not correct, re adjust tensioning roller to 5 mm.





- Check dimension -a- of belt guard with feeler gauge.
Dimension -a- = 1 mm (0.0393 inch)

Right cover, adjusting
- Turn crankshaft until all bolts -arrows are exposed.
- Loosen all bolts -arrows- of cover.
- Adjust dimension -a- using feeler gage to 1 mm (0.0393 inch).





- Check dimension -a- of belt guard with feeler gauge.
Dimension -a- = 1 mm (0.0393 inch)

Left cover, adjusting
- Turn crankshaft until all bolts -arrows are exposed.
- Loosen all bolts -arrows- of cover.
- Adjust dimension -a- using feeler gauge to 1 mm (0.0393 inch).