Removal and Installation

Toothed Belt, Removing, Installing and Tensioning

Special tools and equipment






- 3242 Clamping bolt
- 3032 Puller
- 3391 Camshaft clamp
- V.A.G 1331 Torque wrench (550 Nm)
- V.A.G 1332

Removing

- Remove ribbed V-belt first.





- Position crankshaft to top dead center No. 3 cylinder. Mark on toothed belt guard -A- must align with notch on belt pulley-B.





- Check position of camshaft sprockets. Larger holes in securing plate -arrows- must align opposite one another on inside.

Note: If the larger are positioned to the outside, the crankshaft must be turned one revolution further.

- Remove sealing plugs from cylinder block, left. Crankshaft TDC drilling must be visible (or be able to be felt) in sealing plug hole.





- Screw clamping bolt 3242 into hole so that crankshaft is secured against turning.
- Remove tensioner for ribbed V-belt.
- Remove center and right-hand toothed belt guards.
- Mark direction of rotation of toothed belt.





- Using 8 mm hex wrench, turn toothed belt tensioner roller-1- counter-clockwise, opposite direction shown (arrow), until tensioning lever-2 compresses tensioner-3- so that spring clamp (2 mm dia.) can be inserted into bore and lifter.

Note:
- The toothed belt tensioning element is oil damped and can therefore only be pushed together slowly.
- The spring pin from 2024 A can be used to secure the tensioning element.

- Remove crankshaft vibration damper.





- Remove fan retainer and belt pulley toothed belt protection.
- Take off toothed belt.

Installing
- Remove securing bolts for camshaft sprocket and take off securing plate.
- Fit an M10 bolt into hole as a counter hold for puller 3032.





- Release camshaft sprocket with puller 3032. Then using securing bolts and securing plates tighten hand tight again.

Note: It must be possible to just turn the camshaft pulleys on the camshaft tapers.





- Route toothed belts as shown. Observe direction of rotation for used toothed belts.





- Fit camshaft clamp 3391.





- Using 8 mm hex wrench, turn toothed belt tensioner roller-1 counter-clockwise, opposite direction shown (arrow), until tensioning lever 2- compresses tensioner -3- so that spring clamp (2 mm dia.) can be removed and then remove clamp.
- Before starting engine, preload timing tensioner roller as follows:
- Using a torque wrench with 8 mm hex bit, apply tension to toothed belt clockwise in direction shown (arrow) until a torque of 15 Nm is attained. This ensures tensioner has expanded completely and is properly engaging toothed belt.
- Tighten camshaft sprocket to 55 Nm after pretensioning toothed belt.
- Remove clamping bolt 3242.

The rest of the assembly is basically a reverse of the disassembly sequence.