Ribbed/Toothed Belts & Semi-automatic Toothed Belt Tensioning
Ribbed belt, removing and installing
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
^ 3090 Connecting rod support
Work sequence
- Remove right-hand insulation tray
- Mark direction of rotation on ribbed belt.
- Turn tensioning device in direction of arrow to relieve ribbed belt tension.
- Lock tensioning device with 3090
- Remove or install ribbed belt.
Note:
When installing the ribbed belt, ensure that it fits correctly in the pulley grooves.
- Start engine and check belt running.
- Belt drive without A/C compressor
- Belt drive with A/C compressor
Toothed belt, removing, installing and tensioning
(Adjusting control times)
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
^ 10-222 A Support
^ 10-222 A/8 Adapter
^ VAG 1331 Torque wrench
5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAG 1332 Torque wrench
40 to 200 Nm (30 to 148 ft. lbs.)
^ T 10020 Two hole nut wrench
10-222 A/21 guide from 10-222 A support tool, modifying
- Use 0-222A support tool to support engine/transmission.
- To fasten 10-222 A/8 adapter to 10-222 A/21 guide; drill a new hole.
Dimensions are in mm.
- One hole 12.5 mm (arrow) drilled in 10-222 A/21 guide
Removing
- Remove right-hand insulation tray
=> General body repairs
- Remove engine cover.
- Remove ribbed belt => Refer to Ribbed belt, removing and installing.
- Remove ribbed belt tensioning element.
- Turn crankshaft to cyl. 1 TDC.
- Remove toothed belt guard - upper section
- Install 10-222A support with legs 10-222A/1 as shown.
- Remove engine mount -1- as follows:
- Unscrew bolts -arrows-
- Loosen bolt -arrow A-
- Remove vibration damper/belt pulley.
- Install toothed belt guard center and lower sections.
- Unscrew engine bracket from engine block
Note:
To loosen front screw of bracket; raise engine slightly using the support.
- Mark engine direction of rotation on toothed belt.
- Release tensioner and take off toothed belt.
- Turn crankshaft back slightly.
Installing
Note:
If piston is at TDC; the valves could strike the piston when turning the camshaft.
A - Toothed belt completely removed
If toothed belt has only been removed from camshaft
=> Refer to 10-222 A/21 guide front 10-222 A support tool, modifying.
Conditions
^ Pistons must NOT be positioned at TDC.
Work sequence
- Bring mark on camshaft into line with the mark on toothed belt guard.
- Place toothed belt on crankshaft pulley and coolant pump (observe engine direction of rotation).
- Install bracket to engine block.
^ 45 Nm (33 ft. lbs.)
Note:
Insert screws before installing engine support.
- Install toothed belt guard center and lower sections.
- Install vibration damper/belt pulley
^ Tightening torque: 25 Nm (18 ft. lbs.)
- Turn crankshaft to cyl. 1 TDC
- Install engine mount (replace bolts).
- Remove 10-222 A support.
- Place toothed belt on tensioning roller and camshaft sprocket and tension.
B - Toothed belt, removed from camshaft sprocket only
Conditions
^ Pistons must NOT be positioned at TDC.
Work sequence
- Align mark on camshaft with line on toothed belt guard.
- Turn crankshaft to TDC cyl. 1.
- Place toothed belt on camshaft sprocket and tension
Toothed belt, tensioning Requirements
^ Engine must be warm to the touch
^ Camshaft sprocket at cyl. 1 TDC.
- Tension toothed belt by turning eccentric to left with T 10020 2 hole wrench until notch -1- and indicator -2- align.
- Tighten securing nut
^ 20 Nm (5 ft. lbs.)
- Turn crankshaft two rotations in engine engine direction of rotation and check toothed belt tension again.
- Install toothed belt guard, upper section.
- Install ribbed belt tensioner.
^ Tightening torque: 25 Nm (18 ft. lbs.)
- Install ribbed belt.
- Install sound dampening pan and engine cover.
Semi-automatic toothed belt tensioning roller, checking
Installation position
^ Angled retainer -arrow- must be located in cut-out on cylinder head.
Test sequence
- Place camshaft sprocket on cyl. 1 TDC
- Note position of pointer -2- (using mirror).
- Tension toothed belt with firm thumb pressure.
^ Notch -1- and indicator -2- must move apart.
- Release thumb pressure on toothed belt.
^ Tensioning roller must move back to its initial position (notch - 1- and indicator -2- align again).
^ Tension roller must return to initial position
^ With engine cold to warm to the touch; notch -1- and pointer -2- must be across from one another