Removal and Replacement
Toothed belt, removing, installing and tensioning
Special tools and equipment
- V.A.G 1331 torque wrench (5...50 Nm)
- V.A.G 1332 torque wrench (40...200 Nm)
Tensioning roller up to 07.00 (not adjustable)
- T10092 tensioning bolt
- T40011 pin
Tensioning roller from 08.00 (must be adjusted)
- 3387 pin wrench
- T10008 locking plate
Removing
- Bring lock carrier into service position Lock Carrier And Front Bumper Reinforcement, Moving to Service Position
- Remove ribbed belt [1][2]Procedures
- Remove tensioning element for ribbed belt.
- Remove toothed belt guard upper.
- Mark direction of rotation of toothed belt.
- Adjust camshaft to TDC cylinder 1.
- Remove harmonic balancer/belt pulley.
- Remove lower and center toothed belt guard.
Tensioning roller up to 07.00 (not adjustable)
- Thread T10092 tensioning bolt into tensioning device for toothed belt.
- If necessary, align pressure piston before tensioning, using needle nose pliers or thin wire (hole in pressure piston and hole in housing must overlap.
- Tighten pressure piston only far enough so that the pressure piston can be secured using T40001 pin.
Tensioning roller from 08.00 (must be adjusted)
- Insert an hex wrench into hex socket up to stop and press tensioning roller in counter clockwise direction (in direction of arrow) with uniform non-excessive force until the tensioning device of the toothed belt can be aligned using T10008 locking plate.
Note: Toothed belt tensioning device is an oil damper device and can only be compressed slowly and with equal force. Excessive force during compression can damage tensioning roller.
- To loosen toothed belt, loosen nut -1 of tensioning roller and turn pin wrench in direction of arrow using 3387 pin wrench.
Note: Impact tab -A- of pin wrench must not be bent.
Continuation for all
- Remove toothed belt.
- Then turn crankshaft back slightly.
Installing
Requirement
- Pistons must not be positioned in TDC.
Work sequence
- Align mark on camshaft gear and mark at cylinder head cover.
- Install toothed belt on crankshaft gear (note direction of rotation)
- Install toothed belt guard, lower.
- Install harmonic balancer/belt pulley using new bolts.
Tightening torque: 10 Nm + 1/4 turn (90°) additional
- Adjust crankshaft to TDC cylinder 1.
- Install toothed belt in the order coolant pump, tensioning roller, camshaft gear.
- Tighen toothed belt.
Tensioning toothed belt
Requirements
- Engine must not be more than hand warm.
- Engine is at TDC cylinder 1.
Work sequence
Tensioning roller up to 07.00 (not adjustable)
- Tension toothed belt by pulling out T40001 pin and unbolting T10092 tensioning bolt.
Tensioning roller from 08.00 (must be adjusted)
Note: If the toothed belt tensioning device is completely extended, it must be pressed back in installed position with the tensioning roller. This procedure can take up to 5 minutes. Excessive force during compression can damage tensioning roller.
- Turn pin wrench counterclockwise (tab -A- of pin wrench must not be bent) using 3387 pin wrench until T10008 locking plate can be removed without tension.
- Turn pin wrench to the right in clockwise direction (direction of arrow) until a drill bit -2- with dimension -a- can be pulled through tensioning lever and housing of tensioning device.
Specified value dimension -a- 8 mm.
- Hold tensioning roller in this position and tighten securing nut of tensioning roller as follows:
Specified value: 27 Nm
Continuation for all
- Turn crankshaft two rotations and check whether the camshaft and crankshaft marks align with their reference points.
Tensioning roller from 08.00 (must be adjusted)
- Check dimension -a- using a drill bit -2 between tensioning lever and housing of tensioning device.
Specified value: 6...10 mm
If dimension -a- is not being reached
- Repeat procedure
If dimension -a- is being reached
Continuation for all
- Toothed belt guard, install center and upper part.
- Install tensioning device for ribbed belt.
Tightening torque: 25 Nm
- Install ribbed belt [1][2]Procedures