Jetta L4-1.9L DSL Turbo (BEW) (2004)
Installing
Note:
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Adjustment work on toothed belts must only be performed on cold engines as the indicator on the tensioning element alters depending on the
engine temperature.
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The tensioning roller must be locked with locking pin T1 0115 and secured to the right limit stop.
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Turn camshaft pulley in elongated holes counter-clockwise in direction of arrow - onto limit stop. Install toothed belt to crankshaft pulley, belt
tensioner and camshaft pulley.
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Install toothed belt onto coolant pump toothed belt pulley.
Note: Ensure that tensioning roller seats correctly in rear toothed belt guard - arrow -.
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Loosen tensioning roller securing nut.
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Relieve tension on tensioning roller by turning pin wrench in opposite direction of arrow and remove locking pin from tensioning roller.
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Carefully turn tensioning roller with pin wrench 3387 in direction of arrow until indicator is in middle of gap in base plate - arrow -.
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Hold tensioning roller in this position and tighten tensioning roller securing nut as follows- 20 Nm and 45° (1/8 turn) further.
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Tighten camshaft pulley securing bolts to 25 Nm.
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Remove locking pin 3359 and crankshaft stop T1 0050.
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Turn crankshaft two rotations in direction of engine rotation and set again to TDC No. 1 cylinder.
Note:
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As this is done, the shaft of the crankshaft stop must be able to engage in the sealing flange from direction of engine rotation.
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If the crankshaft is turned past TDC No. I Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 1/4 turn
to be able to turn the crankshaft in the direction of engine rotation again to set it to TDC No. I cyl. It is not permitted to turn the engine
opposite to the normal direction of rotation when turning to ensure the crankshaft stop will engage.