Toothed Belt, Removing and Installing
4.8 Toothed Belt, Removing and InstallingSpecial Tools and Workshop Equipment Required
- Tightener Pulley Wrench -T40009-
- Locking Pin -3242-
- Torque Wrench -V.A.G 1783-
- Ratchet 1/4" -VAS 1783-
- Puller -T40001-with Claws-T40001/2-
- Camshaft Adjustment -T40005-
- Locking Pin -T40011-
- Spanner Wrench -3212-
Removing
- Remove the engine cover -arrows- first.
- Remove toothed belt cover.
- Remove noise insulation -arrows-.
- Remove ribbed belt.
CAUTION!
Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).
- Position the crankshaft at the toothed belt sprocket center bolt at the cylinder 5 TDC marking in the direction of engine rotation.
^ Notch -B- aligns with marking -A-
Note:
Turning over the engine is performed at the center bolt of the crankshaft.
- Check position of camshafts:
^ The large holes -arrows- on securing plates at camshaft gears must align on inside.
- In case they do not align, turn one more rotation.
- Remove sealing plug -arrow- from cylinder block on left side.
- Top Dead Center (TDC) mark on crankshaft must be behind bore (can be touched) of removed sealing plug.
Warning!
Do not rotate crankshaft while touching TDC mark with finger -danger of injury.
- Screw -3242- in hole for removed locking bolt.
- Remove tensioner for ribbed belt -arrow-.
- Remove rigged belt pulley for viscous fan using -3212-.
- Remove vibration damper of crankshaft after removing 8 attachment bolts -1-.
- Remove torque support -arrows-.
- Remove the torque support bracket -arrows-.
- Remove the center toothed belt guard.
Note:
- Before removing the ribbed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.
- The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure.
- Using an 8mm hex socket wrench, turn toothed belt tensioner in direction of -arrow- until tensioning lever pushes tensioner together far enough so that -T40011- can be inserted into the bores of pistons and housing.
- Loosen bolt -arrows- of eccentric pulley.
- Install -T40005- in locking plates of camshafts.
Note:
The -T40005- serves as a retainer.
- Loosen both bolts for camshafts approximately 5 turns.
- Remove -T40005-.
- Remove both camshaft gears using -T40001-.
- Remove toothed belt gear cyl. banks 1 to 4 together with toothed belt.
Caution!
Check gears after removing. If dents are visible, replace camshaft gears.
Installing
^ Tightening specifications
- Replace bolts -1- for camshaft gears and securing plates -2-.
- Grease threads and head seating surfaces of bolts for camshaft gears.
- Install bolts far enough so that they can still just be turned and do not cant.
- Observe the proper seating of the securing plates on the camshafts.
Before installing toothed belt, make sure crankshafts are set to TDC cylinder 5.
^ The large holes -arrows- on securing plates at camshaft gears must align on inside.
^ -3242- must be screwed in.
- Route toothed belt in the following sequence: Toothed beld gear crankshaft -5-, eccentric pulley -4-, tensioner -6-, toothed belt gear left camshaft -3-, coolant pump -2-.
- At last, place toothed belt on toothed gear of right camshaft -1-.
- Turn tensioning lever twice at 40 Nm in direction of -arrow- to pretension toothed belt.
Note:
In the next two illustrations, depicted with torque support bracket removed, for the sake of illustration.
- Insert a 5mm hex socket wrench flat between tensioning lever -1- and piston -2- of tensioner.
- Tighten toothed belt by turning eccentric pulley using -T40009- and turn -V.A.G 1783- using -VAS 6234- in direction of -arrow- and hold.
^ Pretightening specification: 6Nm
- Tighten eccentric pulley.
Note:
Make sure that the position does not change while tightening.
- Insert -T40005- into securing plates of both camshafts.
^ Press in camshaft adjustment as far as possible.
- Tighten camshaft gears.
Note:
The -T40005- serves as a retainer.
- Remove -T40005-.
- Remove 5mm hex socket wrench.
- Turn tensioning lever using 8mm hex socket wrench in direction of -arrow- until -T40011- can be pulled out.
- Turn crankshaft two complete rotations in direction of engine rotation until crankshaft stands at TDC cyl. 5 again.
^ The large holes -arrow- on securing plates at camshaft gears must align on inside.
- Check dimension -a- between tensioning lever and tensioner housing.
^ Dimension -a- =5.0 +/- 1.0mm
Note:
If dimension -a- is not obtained, repeat adjustment.
- To check timing, bolt -3242- in bore at upper section of oil pan again.
- Check camshaft positions using -T40005-.
Note:
If camshaft locator cannot be inserted, repeat adjustment.
- Remove -T40005- from both cylinder heads.
- Remove -3242-.
- Bolt locking bolt of TDC marking into upper section of oil pan using new sealing ring.
Further installation is in reverse order of removal, note the following:
Note:
^ Replace gaskets, seals and O-rings.
^ Secure all hose connections using hose clamps appropriate for the model type.
- Install ribbed belt.
Note:
^ Only reuse drained coolant if cylinder head or engine block was not replaced.
^ Dirty coolant must not be re-used.