Removing and installing toothed belt for camshaft: VW 2.5 TDI (AGX, AHD, ANJ, APA, …)

AHD ANJ APA BBE BBF
Special tools, workshop equipment, testing and measuring devices and aids

2065 A Adjustment ruler
2068 A Adjustment device for TDC point
3036 Brace
3419 Brace
3435 Brace
V.A.G 1332 Torque spanner
(40 - 200 Nm)

V.A.G 1331 Torque spanner (5 - 50 Nm)

V.A.G 1601 Torque spanner (150 - 800 Nm)

Removing

Remove ribbed V-belt => page
13-18
.
Remove upper section of toothed belt guard.
Remove viscous fan =>page
19-13
, Fig.
2
.
Remove air guide from radiator => page
19-4
, item
13
.
Remove belt pulley for viscous fan.

Remove idler pulley from bracket.
Remove cover of service opening:

=> General Body Repairs External; Repair group 50; Body front; Removing cover of service opening
General Body Repairs External
Body front
Removing cover of service opening

Remove toothed belt guard for both toothed belts and cylinder head cover.
Fit brace 3419 or T10025 and loosen vibration damper/toothed belt sprocket on crankshaft at central bolt.

Turn crankshaft in engine rotating direction to TDC position of cylinder 1:

Engine installed

Markings on injection pump sprocket/bracket and flywheel/clutch bell -arrows- must be aligned.

Note:

This state is only achieved in every 2nd TDC position.

Markings on vibration damper and lower section of toothed belt guard must be aligned -arrows- .

Engine removed

Set adjustment device for TDC 2068 A to 96.9 mm-arrow A-; left notch of vernier gauge is reference point.
Screw in adjustment device as shown. Turn crankshaft until TDC marking on flywheel/drive plate align with edge of adjusting device -arrow B- and markings on injection pump pulley and bracket.

Note:

This state is only achieved in every 2nd TDC position.

Removing toothed belt for injection pump:

=> Repair group 23; Servicing the Diesel Direct Injection System; Removing and Fitting, Tensioning Toothed Belt for Injection Pump
5-Cyl. Diesel Engine, Mechanics
Servicing the Diesel Direct Injection System
Removing and Fitting, Tensioning Toothed Belt for Injection Pump

Unscrew 4 mounting bolts M8 of vibration damper/toothed belt pulley-crankshaft.
Unscrew central bolt for vibration damper.
Remove vibration damper.
Remove toothed belt guard=>page
13-7
, item
13
.
Mark running direction of toothed belt.
Relax tensioner for toothed belt with ring spanner 3355.
Remove toothed belt.

Installing, tensioning

Remove drive pulley for injection pump.
Check whether TDC marking on flywheel and reference mark are aligned.
Lock camshaft in place with adjustment ruler 2065 A.

Centre adjustment ruler as follows:
Turn the locked camshaft until one end of the adjustment ruler strikes the cylinder head. Measure the resulting clearance at the other end of the adjustment ruler with a feeler gauge. Push a feeler gauge with half the clearance dimension between the adjustment ruler and the cylinder head. Now turn the camshaft until the adjustment ruler contacts the feeler gauge. Insert a second feeler gauge with the same dimension between the adjustment ruler and the cylinder head at the other end.

Loosen mounting bolt of camshaft sprocket 1/2 turn. Separate camshaft sprocket from taper of camshaft by striking with a hammer (with drift through hole of rear toothed belt guard).

Install tensioner -1- so that tab -2- of tensioner is seated in anti-twist pin of lower section of toothed belt guard.
Fit toothed belt for camshaft drive. With a used toothed belt, running direction must be observed.
Tighten mounting bolt of tensioner hand-tight.

To tension toothed belt, turn tensioner clockwise -direction of arrow- with ring spanner 3355 until right edge of pointer -A- is aligned with right edge of pointer -B-.

Note:

The right edge of pointer -A- may not be turned past the right edge of pointer -B-, as otherwise there is danger of pre-damage to the tensioner.

However, if it is accidentally turned too far once, the tensioner must be completely relaxed and retensioned. The eccentric may not be turned back only by the dimension it was turned too far.

Tighten mounting bolt of tensioner with
20 Nm.
Check whether crankshaft is still at TDC of cylinder 1 and correct if necessary.

Tighten mounting bolt for camshaft sprocket with brace 3036.
Observe marking for bolt steel on bolt head:
8.8 = 85 Nm
10.9 = 100 Nm
Remove adjustment ruler 2065 A from camshaft.
Install bottom toothed belt guard.

Fit vibration damper with new central bolt.
Insert brace 3419 or T10025 and tighten vibration damper/toothed belt pulley-crankshaft at central bolt with 160 Nm and
180°turn (1/2 turn)
further (turning further can be carried out in several steps).
Tighten 4 mounting bolts M8 of vibration damper/toothed belt pulley-crankshaft with 20 Nm.

Turn crankshaft two turns in engine rotating direction until crankshaft is at TDC for cylinder 1 again.

Check pointer position of tensioner again. If right edges of pointers -A- and -B- do not align, tensioning must be repeated.
Installing toothed belt for injection pump:

=> Repair group 23; Servicing the Diesel Direct Injection System; Removing and Fitting, Tensioning Toothed Belt for Injection Pump
5-Cyl. Diesel Engine, Mechanics
Servicing the Diesel Direct Injection System
Removing and Fitting, Tensioning Toothed Belt for Injection Pump

Install toothed belt guard for both toothed belts and cylinder head cover.
Install cover of service opening:

=> General Body Repairs External; Repair group 50; Body front; Removing cover of service opening
General Body Repairs External
Body front
Removing cover of service opening

Install bracket for viscous fan.
Mount idler pulley on bracket.
Install belt pulley for viscous fan.
Mount air guide on radiator.
Install viscous fan =>page
19-13
, Fig.
2
.
Install ribbed V-belt => page
13-18
.