Toothed Belt, Removing and Installing
Toothed Belt
Special tools, testers and auxiliary items required
- Retainer (3036)
- Locking Pin (3242)
- Torque Wrench (V.A.G 1783)
- Reversible Ratchet (VAS 5122)
- Two-Arm Puller (T40001) with (T40001/2)
- Camshaft Locator (T40005)
- Tightener Pulley Wrench (T40009)
- Locking Pin (T40011)
Toothed Belt, Removing
- Remove lock carrier. Removal and Replacement
- Disconnect the connector -5- on the Charge Air Pressure Sensor (G31).
- Loosen hose clips -3- and -4-.
- Disconnect the hoses from the recirculating valves.
- Remove bolts -1-, -2- and remove the air guide pipe.
- Remove ribbed belt. Ribbed Belt, Removing and Installing
- Remove upper left and right toothed belt guards.
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 TDC marking in the direction of engine rotation.
- Notch -B- aligns with marking -A-.
- 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 nuts -1 to 4- for left and right stabilizer mounts.
- Remove left noise insulation bracket -arrows-.
- Remove the screws -1- and -2-.
- Loosen the hose clamps -arrows- and remove the left air guide pipe.
- Remove locking bolt -arrow- of TDC marking at upper section of oil pan.
CAUTION! Do not rotate crankshaft while touching TDC mark with finger - danger of injury.
- In the crankshaft, a TDC bore is located exactly behind the locking bolt (can be felt by touch).
- Install the (3242) into the hole
- Remove vibration damper of crankshaft after removing 8 attachment bolts -1-.
- Remove the center toothed belt guard.
- Using an 8 mm 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.
- When inserting, the bracket for the torque support remains installed. The locking pin can be guided through a hole in the bracket to be inserted into the holes in the tensioner.
- The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure.
- Before removing the ribbed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the used toothed belt.
- Loosen bolt -arrow- of eccentric pulley.
- Loosen the bolts on both camshaft sprockets approximately two turns. Counterhold it using the (3036) while doing this.
- Remove left and right camshaft gears from cone using (T40001 ) with (T40001/2).
- Remove toothed belt.
Installing (Adjusting valve timing)
- When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.
- 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 crankshaft and camshafts 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 belt gear crankshaft -5-, eccentric pulley -4-, tensioner -6-, toothed belt gear left camshaft -3-, coolant pump -2-.
- At last, place toothed belt on toothed belt gear of right camshaft -1-.
- Turn tensioning lever twice at 40 Nm in direction of -arrow- to pretension toothed belt.
- In the next two illustrations, depicted with torque support bracket removed, for the sake of illustration.
- Insert a 5 mm hex socket wrench between tensioning lever -1- and tensioner piston -2-.
- Use a 3/8 to 1/4 adapter to attach the (T40009).
- Tension toothed belt. Turn the eccentric roller using the (T40009) and (V.A.G 1783) and (VAS 5122) in direction of -arrow- and hold.
- Protection torque: 6 Nm
- Tighten eccentric pulley.
Tightening specification: 45 Nm.
- Make sure that 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.
- The (T40005) serves as a retainer.
- Remove (T40005).
- Remove the 5 mm hex socket
- Turn the tensioning lever using 8 mm hex socket wrench in direction of -arrow- until (T40011) can be pulled out.
- Remove (3242).
- Turn crankshaft two turns in direction of engine rotation until the crankshaft stands at TDC again.
- The large holes -arrows- on securing plates at camshaft gears must align on inside.
- Check dimension -a- between tensioning lever and tensioner housing.
- Dimension -a- = 5.0 ±1.0 mm.
- 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).
- 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:
- Replace gaskets, seals and O-rings.
- Hose connections and charge air system hoses must be free of oil and grease before installing. Do not use lubricant under any circumstances.
- Secure all hose connections using hose clamps appropriate for the model type.
- Install stabilizer bar. Service and Repair
- Install ribbed belt Ribbed Belt, Removing and Installing
- Install lock carrier with attachments. Removal and Replacement
- Install front bumper. Front Bumper
- Install air filter housing
- Fill with coolant. Cooling System, Draining and Filling
- Only reuse drained coolant if cylinder head or engine block was not replaced.
- Dirty coolant must not be re-used.
- Adjust headlamps. Adjustments
Tightening Specifications
