Removal and Replacement
Camshaft Drive Belt, Removing, Installing and Tensioning
(Adjusting timing)
Special tools
^ 10-222 A Support with 1 0-222a/1 adaptor
^ T10020 Two hole nut wrench
^ V.A.G 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft. lbs.) (or equivalent)
^ V.A.G 1332 Torque wrench 40 to 200 Nm (30 to 148 ft. lbs.) (or equivalent)
Removing
- Remove engine cover.
- Remove ribbed belt.
- Remove ribbed belt tensioning element.
Engine installed:
- Turn crankshaft to cyl. 1 TDC (arrow) (Engine with manual transmission shown).
- Turn crankshaft to cyl. 1 TDC (arrow) (Engine with automatic transmission shown).
Engine removed:
- Turn crankshaft damper to cyl. 1 TDC (arrows).
- Remove camshaft drive belt guard - upper section
- Install 10-222A support with legs 10-222A/1 as shown.
- Remove overflow reservoir for coolant (hoses remain connected).
- Remove reservoir for power steering fluid (hoses remain connected).
- Remove bolts (arrows) and engine mount.
- Remove vibration damper/belt pulley.
- Remove camshaft drive belt guard center and lower sections.
- Remove bolts for engine bracket from cylinder block (arrows).
Note:
- To loosen front screw from bracket, raise engine slightly using the support.
- Mark direction of rotation on belt.
- Release belt tension and take off belt.
Installing
Note:
- If piston is at TDC; the valves could strike the piston while turning the camshaft.
A - Camshaft drive belt completely removed
If camshaft drive belt only has been removed from camshaft.
Condition
^ Pistons must NOT be positioned at TDC.
Work sequence
- Bring mark on camshaft into line with the mark on toothed belt guard.
- Place camshaft drive belt on crankshaft pulley and coolant pump (observe engine direction of rotation).
- Install bracket to engine block. Tightening torque: 45 Nm (33 ft. lbs.)
Note:
- Insert screws before installing engine support.
- Install camshaft drive belt guard center and lower sections.
- Install vibration damper/belt pulley. Tightening torque: 40 Nm (30 ft. lbs.)
- Turn crankshaft to cyl. 1 TDC (arrows).
- Install engine mounts (replace bolts).
- Align engine and transmission mounts.
- Install overflow reservoir for coolant. Torque to 10 Nm (7 ft. lbs.).
- Install reservoir for power steering fluid. Torque to 10 Nm (7 ft. lbs.).
- Place camshaft drive belt on tensioning roller and camshaft sprocket and tension.
- Remove 10-222 A support.
B - Camshaft drive belt, removed from camshaft sprocket only
Requirement
^ Pistons must NOT be positioned at TDC.
Work sequence
- Align mark on camshaft with line on camshaft drive belt guard.
- Turn crankshaft to TDC cyl. 1.
- Place camshaft drive belt on camshaft sprocket and tension.
Camshaft drive belt, tensioning
Requirements
^ Engine must be at most warm to the touch
^ Camshaft sprocket at cyl. 1 TDC.
- Tension camshaft drive belt by turning eccentric to left with T 10020 2 hole wrench to stop (arrow).
- Tension is correct when notch - 1 and indicator -2- align (Check using mirror).
- Tighten mounting nut to 20 Nm (15 ft. lbs.)
- Turn crankshaft two rotations in engine engine direction of rotation and check camshaft drive belt tension again It is important that the last 45°(1/8 turn) of rotation is made without interruption.
^ Specification: Notch -1 and indicator - 2 align.
- Install camshaft drive belt guard, upper section.
- Install ribbed belt tensioner and torque to 25 Nm (18 ft. lbs.)
- Install ribbed belt.
- Install sound dampening pan and engine cover.
Semi-automatic toothed belt tensioning roller, checking
Special tools and equipment
^ T10020 toothed belt tensioner
^ Mirror
Installation position
^ Angled retainer (arrow) must be located in cutout on cylinder head.
Requirements
^ Engine must be at most warm to the touch
Test sequence
- Place camshaft sprocket on cyl. 1 TDC
- Note position of pointer -2- (using mirror).
- Turn crankshaft two rotations in direction of engine rotation and check camshaft drive belt tension again. It is important that the last 45° (1/8 turn) of rotation is made without interruption.
- Tensioning roller must move back to its initial position (notch -1- and indicator -2- align again).
Note: Check using mirror.