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Checking semi-automatic toothed belt tensioning roller checking > < Toothed belt removing, installing and tensioning|Removal

Leon Mk2

Installation
Installation
Check conditions
l  The crankshaft sprocket is secured to the crankshaft with a bolt and two washers.
   
l  The camshaft sprockets are locked with tool -T10016- in the holes drilled in the cylinder head and secured against involuntary turning.
Work sequence
–  Set the crankshaft to TDC No. 1 cylinder. The tooth with end ground down must align with the mark on the sealing holder cover.
  Note!
Note that on the oil pump/sealing holder cover there are two TDC marks, one small one for 4V engines (right-hand side) and another longer mark for 2V engines (left-hand side). Do not confuse the marks on setting the crankshaft at TDC or there could be serious damage to the engine.
–  Removing coupling drive toothed belt. The slack section of the toothed belt must be downwards. Note direction of rotation with used belts.
Separate tensioning roller from coupling drive toothed belt as indicated.
  N13-0147
–  Turn the tensioning roller of the coupling drive toothed belt by turning the interior hexagon -1- clockise towards the mark window (tensioning roller slack).
–  Press lower section of toothed belt for coupling the camshaft upwards with tensioning roller and fit tensioning roller securing bolt.
–  Tighten securing bolt by hand. The lug in the base plate must engage in the hole in the cylinder head -2-.
  N13-0364
–  Then, tension the toothed belt by turning the tensioning roller anti-clockwise, turning the interior hexagon -item 1 -, until the indicator -2- coincides with the lug in the mark window -arrow-.
–  Tighten the tensioning roller securing bolt to a torque of 20 Nm.
  Note!
The camshaft must be secured against turning by tool -T10016-, until the main drive toothed belt is fitted.
–  Fit main drive toothed belt on in anti-clockwise direction starting at water pump then via tensioning roller, crankshaft, idler roller and inlet camshaft sprocket. Note direction of rotation with used belts.
If tensioning roller was removed beforehand, install tensioning roller as follows:
  N13-0365
–  Turn tensioning roller of the main toothed belt by turning the roller anti-clockwise, turning the interior hexagon to the indicated position -arrow-.
  N13-0366
–  Fit tensioning roller and tighten bolt by hand. The base plate -1- cut-out must engage over securing bolt -2-.
–  Turn roller with an Allen key, in the direction indicated by the arrow, until the indicator -3- coincides with the notch in the base plate-arrow-.
–  Tighten the tensioning roller securing bolt to a torque of 20 Nm.
–  Remove tool -T10016- from camshaft sprockets.
–  Now turn crankshaft twice in direction of engine rotation until it is again at TDC No. 1 cylinder.
–  Now the position of the toothed belts and tensioning roller must be checked again.
Tension toothed belt again if necessary.
–  Install lower toothed belt guard.
–  Refit crankshaft belt pulley. When doing this note the following:
t  Replace the crankshaft pulley/sprocket securing bolt.
t  On fitting the pulley, note securing with relation to the sprocket.
t  Tighten the new and lubricated securing bolt to 90 Nm + 1/4 turn (90°).
–  Install ribbed belt → Chapter.
  Note!
On fitting the ribbed belt, make sure that it is correctly located on the pulleys.
–  Remove air inlet duct, as well as air intake tubes, air filter → Injection and Ignition System, 4LV; Rep. Gr.24.
–  Fit upper camshaft housing cover.
  N13-0180

Checking semi-automatic toothed belt tensioning roller checking > < Toothed belt removing, installing and tensioning|Removal