Toothed Belt Drive For Balancing Shafts Removing and Installing

Toothed belt drive for balancing shafts, removing, installing and adjusting
Special tools and equipment





^ T10069 Counter-holder
^ VAG 1331 Torque wrench (5...50 Nm)
^ VAG 1332 Torque wrench (40...200 Nm)
^ VAG1601 Torques Wrench(150...800 Nm)

With engine removed:
^ 3242 Clamping bolt

Not illustrated:
^ Drill bit, diameter 2.0 mm

Removing

Note:
^ The toothed belt can be removed and installed when the engine is installed in the engine compartment.
^ The upper and lower balancing shafts can only be removed and installed when the engine Is removed from the engine compartment.

^ Remove ribbed belt.





^ Remove vibration damper securing bolt. To do this, lock vibration damper with counter-holder T10069.





^ Turn crankshaft to TDC No. 1 cylinder.
^ Mark -1- must align with cylinder block joint -2-.
^ Remove vibration damper.

With engine removed:
^ Remove sealing plug from left side of cylinder block, Refer to Clinder Block, Service and Repair, Engine disassembling and assembling.





^ Screw clamping bolt 3242 into hole so that the crankshaft is secured against turning.





When engine is either removed or installed:
^ Remove toothed belt tensioning device securing bolts -1- and -2- and take off tensioning device.
^ Remove toothed belt guard.
^ Mark direction of rotation of toothed belt.
^ Release tension of tensioning roller -2- and lock tensioning roller with a drill bit (diameter: 2.0 mm).





^ Remove tensioning roller -2- for toothed belt -4-.
^ Remove toothed belt.
^ Remove crankshaft toothed belt sprocket -1-.

Installing





^ Install crankshaft toothed belt sprocket -1-.
^ Turn crankshaft to TDC No. 1 cylinder (arrow -A-).

Note: If the crankshaft has not been turned or the clamping bolt 3242 has not been removed, then the crankshaft toothed belt sprocket can be fitted straight on.





When engine is either removed or installed:
^ Line up marking of upper toothed belt gear differential shaft to cylinder block marking (arrows).

With engine removed:
^ Remove flywheel/drive plate sealing flange.





^ Turn upper balancing shaft -3- so that mark (arrow) is positioned straight down.
^ Insert lower balancing shaft -4- so that its mark aligns with mark of upper balancing shaft -3-.
^ Secure balancing shafts with locking plate -1- and tighten securing bolts -2- to torque setting.
Tightening torque: 10 Nm





When engine is either removed or installed:
^ Install toothed belt -4- (note direction of rotation) then install tensioning roller -2-. Ensure tensioning roller alignment (arrow -B-) is correct.
Tensioning roller tightening torque: 25 Nm
^ Tension toothed belt by pulling out drill bit.





When engine is installed in engine compartment:
^ Check again position of marking of upper toothed belt gear differential shaft and cylinder block marking (arrows) to each other. (While doing so, crankshaft is at TDC cylinder 1.)





With engine removed:
^ Check position of balancing shafts -3- and -4- to one another, again.
^ Install flywheel/drive plate sealing flange.
^ Replace seal on flywheel/drive plate sealing flange.





^ Remove clamping bolt 3242.
^ Install sealing plug in cylinder block.
Tightening torque: 20 Nm





When engine is either removed or installed:
^ Install toothed belt guard.
Torque setting: 10 Nm
^ Install toothed belt tensioning device.
Torque settings:
Securing bolt M8 -1-: 25 Nm
Securing bolt M10 -2-: 30 Nm + 90°(1/4 turn)





^ Install vibration damper and lock with counter-holder T10069.
^ Tighten new securing bolt to 100 Nm + 90°(1/4 turn). (The additional turn may be performed in several steps.)

Note:
^ Vibration damper securing bolt must be renewed.
^ Tighten securing bolt with torque wrench VAG 1601.

^ Install ribbed belt.