volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Checking semi-automatic toothed belt tensioning roller > < Removing

Golf Mk4

Installing
Installing
l  The pistons must not be positioned at TDC.
–  Place toothed belt on crankshaft toothed belt pulley and coolant pump (observe direction of rotation).
  Note
t  Engine removed:
t  Beforehand install lower toothed belt guard and vibration damper/belt pulley.
Adjusting valve timing
  Note
When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns.
   
–  Line up mark on camshaft pulley with mark on toothed belt guard.
Engine installed:
  A13-0077
–  Set crankshaft to TDC No.1 cylinder (vehicles with manual gearbox).
  A13-0045
–  Turn crankshaft to TDC No.1 cylinder (vehicles with automatic gearbox).
  Note
t  Vehicles with engine code APF: TDC No. 1 cylinder on vibration damper
t  When engine is removed and engine code APF with automatic gearbox:
  A13-0043
t  Set vibration damper to TDC No. 1 cylinder -arrows-.
–  Fit toothed belt to tensioning roller and camshaft toothed belt pulley.
Tensioning toothed belt
l  The engine must be no more than warm to touch.
l  Camshaft pulley set to TDC No. 1 cylinder.
l  Before tightening toothed belt, turn tensioning roller on eccentric to stop five times in both directions using pin wrench -T10020-.
  A13-0076
–  Tension toothed belt. To do this, turn pin wrench -T10020- on eccentric to left -in direction of arrow- to stop.
–  Then reduce tension on toothed belt until notch -1- and indicator -2- align (use mirror).
–  Tighten securing nut to 20 Nm.
–  Turn crankshaft two full revolutions in direction of rotation until engine is again at TDC No. 1 cylinder. It is important that the last 45° of rotation (1/8 turn) is performed without interruption.
–  Check belt tension again. Specification: indicator and notch align.
Continuation installing toothed belt complete
–  Install centre and lower toothed belt guard.
–  Install vibration damper/belt pulley, torque setting: 25 Nm
–  Fit engine mounting bracket to cylinder block. Torque setting: 45 Nm.
–  Install complete engine mountings.
  Note
Before installing engine mounting insert bolts into mounting.
–  Align engine and gearbox mountings → Chapter.
Torque settings → Chapter.
–  Remove support bracket -10 - 222 A-.
–  Install upper toothed belt guard.
–  Install poly-V-belt tensioning element. Torque setting: 25 Nm.
–  Install poly-V-belt → Chapter.
–  Install coolant expansion tank.
–  Install power steering reservoir.
–  Install right-hand insulation tray: → Rep. Gr.50.
–  Fit engine cover.
  N13-0402

Checking semi-automatic toothed belt tensioning roller > < Removing