Removing and installing toothed belt, vehicles ► 12.05 — VW

Removing and installing toothed belt, vehicles ► 12.05
Note
From 01.06 a modified engine support has been introduced, it is no longer necessary to remove the engine support and support the engine for the procedure "Removing, installing and tensioning toothed belt".
1
: Engine support ► 12.05 (removal necessary)
Chapter
2
: Engine support 01.06 ► (removal not necessary).
Removing
Special tools and workshop equipment required
Diesel injection pump locking pin
3359
2-hole pin wrench
T10020
Locking pin
T10115
Crankshaft stop
T10050
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Counterhold tool
T10172
Special wrench, long reach
T10264
Support bracket
10 - 222 A
with
adapter
10 - 222 A /23
and
adapter
10 - 222 A /16
Removing
Remove bulkhead on left and right
General body repairs, exterior
Rep. gr.
50
Plenum chamber bulkhead
.
Unbolt right cover and battery cover from lock carrier
Rep. gr.
63
.
Remove any noise insulation
General body repairs, exterior
Rep. gr.
50
Body, front; Noise insulation
.
Remove charge air pipe
1
between charge air cooler and turbocharger.
Carefully cover or seal open ends.
Remove connecting hose
1
from air filter and crankcase breather hose
2
.
Remove poly V-belt
Chapter
.
Remove pin from poly V-belt tensioning element.
Remove tensioning element
Item
.
Remove upper toothed belt guard.
Remove vibration damper/belt pulley
Item
.
Unclip cover caps on suspension strut turret.
Fit
adapter
10 - 222 A /23
1
on foremost suspension strut turret and on lock carrier
arrows
.
Bolt
support bracket
10 - 222 A
to respective
adapter
10-222A/23
Support engine on lifting eyes on cylinder head, using
adapter
10 - 222 A /23
and
adapter
10 - 222 A /16
Remove securing bolts from assembly mounting to engine bracket, assembly mounting to body
arrows
and completely remove assembly mounting.
Note
The assembly mounting may only be removed if the engine is supported with
support bracket
10 - 222 A
!
The engine bracket must be loosened only when the assembly mounting has been removed.
Unbolt engine bracket from cylinder block
arrows
and remove.
Note
When loosening both upper engine bracket bolts the engine must be raised slightly with the support bracket.
When loosening the lower engine bracket bolt the engine must be lowered slightly with the support bracket.
Remove centre and lower toothed belt guards.
Set engine to TDC No. 1 cylinder.
Note
Turn crankshaft until marking on crankshaft toothed belt pulley and tooth segment of camshaft pulley is on top. The arrow on the rear toothed belt guard must align with the markings on the camshaft sender wheel
arrows
.
Lock hub with
diesel injection pump locking pin
3359
. To do this, insert
locking pin
3359
through free elongated hole on left into hole in cylinder head.
Lock crankshaft toothed belt pulley in position with
crankshaft stop
T10050
. To do this, push
crankshaft stop
T10050
into teeth of toothed belt pulley from latter's face side.
Note
The markings on the crankshaft toothed belt pulley and the crankshaft stop must align. At the same time, the pin of the
crankshaft stop
T10050
must engage in the drilling in the sealing flange.
Mark direction of rotation of toothed belt.
Loosen securing bolts
1
of camshaft pulley until camshaft pulley can be moved within elongated holes.
Loosen tensioning roller securing nut.
Note
From 01.06 ►, a new toothed belt tensioner is installed. The tensioner has an additional hexagon hole
arrow
. Use
angle driver
T10264
instead of
2-hole pin wrench
T10020
to loosen and tension the toothed belt. This does not alter the procedure.
Turn
2-hole pin wrench
T10020
anti-clockwise until toothed belt tensioning roller can be locked using
locking pin
T10115
.
Turn
2-hole pin wrench
T10020
clockwise as far as stop and hand-tighten securing nut
1
.
Remove toothed belt first from coolant pump and then from remaining toothed pulleys.
Installing
Camshaft locked with
locking pin
3359
.
Crankshaft locked in position with
crankshaft stop
T10050
.
Tensioning roller locked with
locking pin
T10115
and secured to right stop.
Note
Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.
Turn camshaft pulley in its elongated holes to centre position
arrows
.
Fit toothed belt to crankshaft toothed belt pulley, tensioning roller, camshaft pulley and idler roller.
Finally, fit toothed belt on coolant pump toothed belt pulley.
Note
Ensure that belt tensioner seats correctly in rear toothed belt guard
arrow
.
Undo securing nuts of tensioning roller and pull out
locking pin
T10115
.
Note
From 01.06 ►, a new toothed belt tensioner is installed. The tensioner has an additional hexagon hole
arrow
. Use
angle driver
T10264
instead of
2-hole pin wrench
T10020
to loosen and tension the toothed belt. This does not alter the procedure.
Now carefully turn tensioning roller clockwise using
2-hole pin wrench
T10020
until indicator is in middle of gap in base plate
arrow
.
Ensure that securing nut does not turn as well.
Hold tensioning roller in this position and tighten securing nut of tensioning roller.
Fit
counterhold
T10172
with
pin
T10172/4
as shown. Press
counter-hold tool
T10172
in direction of arrow and keep camshaft sprocket in pretensioning position.
In this position, tighten camshaft pulley securing bolts
1
.
Remove
locking pin
3359
and
crankshaft stop
T10050
.
Turn crankshaft two revolutions in direction of engine rotation until crankshaft is just before TDC for No. 1 cylinder.
Lock hub with
locking pin
3359
whilst turning engine in direction of rotation.
Check whether crankshaft can be locked with
crankshaft stop
T10050
.
If crankshaft cannot be locked:
Loosen securing bolts
1
of camshaft pulley.
Turn crankshaft slightly against direction of engine rotation until pin of
crankshaft stop
T10050
is positioned just before hole in sealing flange
arrow
.
Now turn crankshaft in direction of engine rotation until pin of
crankshaft stop
T10050
engages in sealing flange whilst turning.
Fit
counterhold
T10172
with
pin
T10172/4
as shown. Press
counter-hold tool
T10172
in direction of arrow and keep camshaft pulley in pretensioning position.
In this position, tighten camshaft pulley securing bolts
1
.
Remove
locking pin
3359
and
crankshaft stop
T10050
.
Turn crankshaft two revolutions in direction of engine rotation until crankshaft is just before TDC for No. 1 cylinder.
Repeat measurement.
Install lower toothed belt guard and vibration damper/belt pulley
Item
.
Install middle toothed belt guard.
Using new securing bolts
arrows
, mount engine bracket on cylinder block and tighten securing bolts.
Note
Before installing assembly mounting, tighten all engine bracket bolts to specified torque.
Install assembly mounting between engine and body (renew securing bolts)
Chapter
.
Fit engine assembly mounting to engine bracket by bringing contact surfaces together using
support bracket
10 - 222 A
and tighten
Chapter
.
Install poly V-belt
Chapter
.
Install tensioning element
Item
.
Install upper toothed belt guard.
Install charge air cooler/turbocharger and air filter/turbocharger connecting pipes.
Install any noise insulation
General body repairs, exterior
Rep. gr.
50
Noise insulation
.
Install bulkhead on left and right
General body repairs, exterior
Rep. gr.
50
Plenum chamber bulkhead
.
Install right cover and battery cover on lock carrier.
Specified torques
Chapter
“
Assembly overview - toothed belt drive
”
Chapter
“
Assembly overview - assembly mountings
”
Chapter
“
Assembly overview - poly V-belt drive
”
Chapter
“
Assembly overview - charge air system
”
Noise insulation; Assembly overview - noise insulation
Rep. gr.
50
Assembly overview - noise insulation