Volkswagen Workshop Service and Repair Manuals

Removing, installing and tensioning toothed belts

Special tools and workshop equipment required

t	Locking pin for diesel injection pump -3359-

t	Pin wrench -3387-

t	Locking plate -T10008-

t	Crankshaft stop -T10050-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t  Support bracket -10 - 222 A- with rack -10 - 222 A /1- t  Drill bit, Ø 4 mm Removing   Note Always perform adjustment work on toothed belts only on cold engines. –  Remove engine cover. –  Remove connecting pipe between charge air cooler and intake connection. –  Remove air mass meter. –  Remove noise insulation tray → Rep. Gr.50. –  Unbolt pendulum support from gearbox. –  Remove poly V-belt → Chapter. –  Remove tensioning element for poly-V-belt. –  Remove toothed belt guard upper part. –  Detach fuel line from cylinder head cover.

–  Fit support bracket -10 - 222 A- as shown and support engine in installation position.

–  Remove bolts from engine assembly mounting -arrows- and remove complete assembly mounting. –  Remove engine bracket from cylinder head. –  Remove centre toothed belt guard. –  Lower engine carefully so that the vibration damper/belt pulley can be removed. –  Remove lower toothed belt guard. –  Turn crankshaft to TDC No. 1 cylinder.   Note

Turn the crankshaft until the mark on the crankshaft pulley is facing up and the arrow on the rear toothed belt guard aligns with the lug on the hub sender wheel -arrows-. –  Lock the hub using locking pin for diesel injection pump -3359-. To do this, slide diesel injection pump locking pin -3359- through the free elongated hole on left into hole in cylinder head. –  Lock crankshaft toothed belt pulley with crankshaft stop -T10050-. To do this, slide crankshaft stop -T10050- from face side of toothed belt pulley into teeth.   Note The marks on the crankshaft toothed belt pulley and the crankshaft stop -T10050- 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.

–  Insert a hexagon key into the hexagon hole onto stop and use it to press the tensioning roller anti-clockwise in -direction of arrow- until the toothed belt tensioning device can be locked with the locking plate -T10008-.   Note If the hexagon key is not inserted deeply enough there is a risk of it slipping out. –  Loosen tensioning roller securing nut.

–  Unscrew and remove securing bolts -1- of toothed belt tensioner and remove tensioning element. –  Remove toothed belt. Installing   Note Always perform adjustment work on toothed belts only on cold engines.

–  Loosen securing bolts -1- of camshaft toothed belt pulley until camshaft pulley can be moved within the elongated holes. –  Turn camshaft pulley clockwise -direction of arrow- in elongated holes onto stop.

–  Now carefully turn eccentric clockwise using pin wrench -3387- until eccentric lug lies directly before limit stop -B-. –  Fit toothed belt on camshaft toothed belt pulley, belt tensioner, crankshaft toothed belt pulley and finally water pump toothed belt pulley. –  Install toothed belt tensioning device.

–  Turn eccentric anti-clockwise using pin wrench -3387- (lug of eccentric moves in direction of limit stop -A-), until the locking plate -T10008- is not under tension and can be pulled out. –  Release force of tensioning element in clockwise direction (lug of eccentric moves towards stop -B-) until dimension -a- has been attained. Specification dimension -a-: 4 ± 1 mm   Note t  Measurement -a- reduces when the tensioning roller securing nut is tightened. Therefore adjust generously using Ø 4 mm drill bit. t  Measurement -a- may be reduced to 1 mm if engine is at operating temperature. –  Hold tensioning roller in this position and tighten tensioning roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.

–  Tighten securing bolts -1- of camshaft pulley to 25 Nm. –  Remove locking pin for diesel injection pump -3359- and crankshaft stop -T10050-. –  Turn crankshaft two rotations in engine direction of rotation and set again to TDC No. 1 cylinder.   Note t  When doing this, the pin of the crankshaft stop -T10050- must engage in the sealing flange from the rotational movement. t  If the crankshaft is turned past TDC No. 1 cylinder and the crankshaft stop -T10050- could not engage in the sealing flange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in engine direction of rotation again to set it to TDC No. 1 cylinder. Corrections to the position by turning against engine direction of rotation in order to insert the crankshaft stop -T10050- are not permissible. –  Once the crankshaft stop -T10050- has engaged, check whether: 1. dimension -a- is reached and 2. the hub can be locked using locking pin for diesel injection pump -3359-. If dimension -a- is not attained: –  Tension the tensioning roller again. To do this, hold tensioning roller with 2-hole pin wrench -3387-, loosen securing nut and release force of tensioning device until dimension -a- is attained. Specification dimension -a-: 4 ± 1 mm –  Tighten securing nut to 20 Nm and 45° (1/8 turn) further. If the hub cannot be locked: –  Pull the crankshaft stop -T10050- pin out of the drilling in the sealing flange and turn the crankshaft until the hub can be locked with the locking pin for diesel injection pump -3359-.

–  Loosen securing bolts -1- of camshaft pulley.

–  Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop -T10050- is positioned just before the hole in the sealing flange -arrow-. –  Now turn crankshaft in engine direction of rotation until pin of crankshaft stop -T10050- engages in sealing flange from rotational movement. –  Tighten securing bolts of camshaft belt pulley to 25 Nm. –  Remove locking pin for diesel injection pump -3359- and crankshaft stop -T10050-. –  Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.   Note t  When doing this, the pin of the crankshaft stop -T10050- must engage in the sealing flange from the rotational movement. t  If the crankshaft is turned past TDC No. 1 cylinder and the crankshaft stop -T10050- could not engage in the sealing flange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in engine direction of rotation again to set it to TDC No. 1 cylinder. Corrections to the position by turning against engine direction of rotation in order to insert the crankshaft stop -T10050- are not permissible. –  Repeat check. –  Install lower toothed belt guard and pulley vibration damper. –  Install centre toothed belt guard. –  Fit engine bracket to cylinder block. Torque setting: 45 Nm. –  Install engine mounting. Torque settings → Chapter. –  Install poly V-belt → Chapter. –  Install noise insulation tray → Rep. Gr.50. –  Install upper toothed belt guard. –  Install connecting pipes between air filter and turbocharger and between charge air cooler and intake connecting flange.