Volkswagen Workshop Service and Repair Manuals

Vehicles with hydraulic tensioning system

Identification: with belt tensioning damper -arrow-   Note Always perform adjustment work on toothed belts only on cold engines. Removing –  Remove poly V-belt → Chapter. –  Remove poly V-belt tensioner. Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR: –  Remove right headlight → Rep. Gr.94. –  Remove charge air pipe between charge air cooler and turbocharger → Chapter. Continuation for all vehicles –  Remove coolant expansion tank (coolant hoses remain connected). –  Unscrew power steering reservoir and fuel filter and place to one side (hoses remain connected). –  Detach fuel line from cylinder head cover.   WARNING t  The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! t  The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! t  Wear eye and hand protection when performing any type of repair work on the fuel system!

–  Fit support bracket -10-222A- and take up weight of engine in installation position.

–  Unscrew securing bolts from assembly mounting/engine bracket, assembly mounting/body and assembly mounting/body bracket -arrows- and remove assembly mounting complete.   Note t  The assembly mounting may only be removed if the engine is supported with support bracket -10-222A-! t  The engine bracket must be loosened only when the assembly mounting has been removed.

–  Unbolt engine bracket from cylinder block -arrows- and remove.   Note t  When loosening both upper engine mounting bolts the engine must be raised slightly with the support bracket. t  When loosening the lower engine mounting bolt the engine must be lowered slightly with the support bracket. –  Remove vibration damper/belt pulley. –  Remove centre and lower toothed belt guards. –  Turn crankshaft to TDC No. 1 cylinder.   Note

Turn crankshaft until mark on crankshaft toothed belt pulley is at the top and arrow on rear toothed belt guard aligns with the lug on hub sender wheel -arrows-. –  Lock the hub using diesel injection pump locking pin -3359-. To do this, slide locking pin 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 into teeth of toothed belt pulley from its face side.   Note The marks on the crankshaft toothed belt pulley and the crankshaft stop must align. When doing this, the pin of the crankshaft stop must engage in the drilling of 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 marking plate -T10008-.   Note If the Allen key is not inserted deeply enough there is a risk of it slipping out. –  Loosen tensioning roller securing nut.

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

–  Loosen securing bolts -1- of camshaft pulley until the 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 with pin wrench 3387 until eccentric lug is located directly before limit stop -B-. –  Fit toothed belt on camshaft belt pulley, tensioning roller, crankshaft belt pulley and finally on coolant pump belt pulley. –  Install toothed belt tensioning device.

–  Turn eccentric using pin wrench -3387- anti-clockwise (lug of eccentric moves in direction of limit stop -A-) until marking plate -T10008- can be pulled out without resistance and dimension -a- is less than 4 mm. –  Tension toothed belt by releasing force of tensioning device clockwise (lug of eccentric thereby moves in direction of limit stop -B-) until measurement -a- is reached. Specification -a-: 4 ± 1 mm.   Note t  Dimension -a- is reduced 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 bolts -1- of camshaft toothed belt 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 crankshaft stop pin must engage in the sealing flange whilst turning. t  If the crankshaft is turned past TDC no. 1 cylinder and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 1/4 turn so that the crankshaft can again be turned in engine direction of rotation to allow it to be set to TDC no. 1 cylinder. Making corrections against engine direction of rotation in order to insert the crankshaft stop is not permissible. –  Once crankshaft stop -T10050- has been inserted, check whether: 1.) Dimension -a- can be reached. 2.) The hub can be locked using locking pin for diesel injection pump -3359-. If dimension -a- is not achieved: –  Tension the tensioning roller again. To do this, counterhold tensioning roller using pin wrench -3387-, loosen securing nut and adjust counterforce of tensioning device until measurement -a- is achieved. Specification -a-: 4 ± 1 mm. –  Tighten securing nut to 20 Nm and 45° (1/8 turn) further. If the hub cannot be locked: –  Pull crankshaft stop pin out of drilling in sealing flange and turn crankshaft until hub can be locked with locking pin.

–  Loosen securing bolts -1- of camshaft pulley.

–  Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-. –  Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning. –  Tighten securing bolts of camshaft belt pulley to 25 Nm. –  Remove locking pin for diesel injection pump -3359- and crankshaft stop -T10050-. –  Turn crankshaft 2 rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.   Note t  When doing this, the pin of the crankshaft stop 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 could not engage in the sealing flange, turn the crankshaft back 1/4 turn so that the crankshaft can again be turned in engine direction of rotation to allow it to be set to TDC no. 1 cylinder. Making corrections against engine direction of rotation in order to insert the crankshaft stop is not permissible. –  Repeat check. –  Install lower toothed belt guard and vibration damper/pulley. –  Install centre toothed belt guard.

–  Fit engine bracket to cylinder block and tighten -arrows-. Specified torque: 45 Nm. –  Install upper toothed belt guard.   Note Before installing assembly mounting, tighten all engine bracket bolts to specified torque. –  Install engine to body assembly mounting(renew securing bolts). Tightening torque: 40 Nm + 90° (1/4 turn) –  Align assembly mounting on engine side → Chapter Aligning assembly mounting for engine and gearbox. –  Fit engine assembly mounting to engine bracket by bringing contact surfaces together using support bracket -10-222 A-. Specified torque: 100 Nm. –  Install assembly mounting bracket on body. Specified torque: 25 Nm. –  Install coolant expansion tank. –  Install power steering reservoir and fuel filter. Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR –  Install charge air pipe between charge air cooler and intake connecting pipe → Chapter. –  Install right headlight → Rep. Gr.94. Continuation for all vehicles –  Install poly V-belt tensioning element. Specified torque: 25 Nm. –  Install poly V-belt → Chapter. –  Install noise insulation.