Toothed Drive Belt, Removing, Installing and Tensioning
Toothed drive belt, removing, installing and tensioning
(Adjusting valve timing)
Special tools and equipment
^ V.A.G 1331 torque wrench (5 to 50 Nm)
^ Locking plate T10008
^ V.A.G 1332 (40 to 200 Nm) torque wrench
^ Special tool 3387
Removing
^ With engine in vehicle.
^ Move upper radiator mount to service position, Refer to Body and Frame, Radiator Support, Service and Repair.
^ Remove engine cover by lifting up -arrows-.
^ Remove ribbed belt.
^ Remove ribbed belt tensioner -arrows-.
^ Remove upper part of drive belt cover.
Note: Take special note of the installed position of the upper part of the drive belt cover, particularly where it meets the center part of the drive belt cover.
CAUTION: The engine must only be turned in the direction of engine rotation (clockwise) at the crankshaft.
Note: To turn the engine over use the center bolt on the crankshaft.
^ Bring engine to TDC cylinder 1 by turning crankshaft in direction of engine rotation, using center camshaft drive sprocket bolt on crankshaft. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1 -arrows-.
^ Unbolt vibration damper.
^ Remove center and lower part of drive belt cover.
CAUTION:
^ The drive belt tensioner is oil-damped and can only be compressed slowly and with evenly applied force.
^ When compressing the tensioner, excessive force can damage the tensioning pulley.
^ Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T10008.
Note: The stop tab of the eccentric bolt must not be bent.
^ To release tension from drive belt, loosen nut -1- on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool 3387.
^ Mark direction of rotation of drive belt with chalk or felt tip pen.
^ Remove drive belt.
Installing (adjusting valve timing)
Note:
^ Even with repairs which require the drive belt to be removed only from the camshaft sprocket, the drive belt adjustment must be performed as follows.
^ When rotating the camshaft the crankshaft must not be at TDC for any cylinder. Risk of damaging valves/piston crown.
^ Place drive belt on crankshaft sprocket (observe direction of rotation).
^ Install lower part of drive belt cover.
Note: The vibration damper/pulley can be installed in only one position. The hole -arrow- in the vibration damper must be located over the raised part on the crankshaft drive belt sprocket.
^ Tighten vibration damper/pulley, take note of locating point -arrow-.
^ Align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-drive belt cover positioning marks.
^ Install drive belt in this order: water pump, tensioning pulley, camshaft sprocket.
Tensioning drive belt
If the drive belt tensioner is completely extended
CAUTION:
^ If the drive belt tensioner is at its travel limit, it must be pushed back in the installed position together with the pulley. This procedure can take up to 5 minutes.
^ When compressing the tensioner, excessive force can damage the tensioning pulley.
^ Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T10008.
All
Note: The stop tab of the eccentric bolt must not be bent.
^ Turn eccentric bolt counter-clockwise in direction of arrow using special tool 3387.
^ Hold eccentric bolt in this position and withdraw locking plate T10008.
^ Turn eccentric bolt clockwise to right in direction of arrow until a gauge -2- with dimension -a- (e.g. drill bit) can be passed between tensioning lever and tensioner housing.
^ Dimension a = 8 mm
^ Hold eccentric bolt in this position and tighten pulley nut -1-.
Tightening torque: 27 Nm
CAUTION: The engine must only be turned in the direction of engine rotation (clockwise) at the crankshaft.
Note: To turn the engine over apply tool at the center bolt on the crankshaft.
^ Turn crankshaft two complete turns in direction of engine rotation until crankshaft is at TDC again.
Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1 -arrows-.
^ Check dimension -a- between tensioning lever and tensioner housing with a gauge -2- (e.g. drill bit).
^ Dimension a = 6 - 10 mm
If dimension -a- is not obtained
CAUTION:
^ The drive belt tensioner is oil-damped and can only be compressed slowly and with evenly applied force.
^ When compressing the tensioner, excessive force can damage the tensioning pulley.
^ Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T10008.
^ Loosen nut -1- on pulley.
^ Continue under"Tensioning drive belt, Refer to Toothed Drive Belt, Removing, Installing and Tensioning.
If dimension -a- is obtained
^ Install center and upper drive belt cover.
^ Install ribbed belt tensioner.
^ Install ribbed belt.
Tightening Torques
1) Install using locking adhesive- Parts Supplier
2) Replace bolts
3) 90° equals one quarter turn