volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Checking semi-automatic toothed belt tensioner > < Removing toothed belt

Golf Mk5

Installing toothed belt
Installing toothed belt
  Note
t  When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns.
t  The engine must be no more than warm to touch.
–  Place toothed belt on crankshaft toothed belt pulley and coolant pump (observe direction of rotation).
   
–  Line up mark on camshaft toothed belt pulley with mark on toothed belt guard.
–  Install centre and lower toothed belt guard.
–  Install belt pulley with vibration damper using new bolts. Specified torque: 10 Nm + 90° turn further.
  A13-0691
–  Turn crankshaft at vibration damper to TDC No. 1 cylinder -arrows-.
–  Fit toothed belt to tensioning roller and camshaft toothed belt pulley.
  Note
  A13-0076
Check that tensioning roller is seated correctly in cylinder head.
  A13-0078
–  Tension toothed belt. To do this, turn 2-hole pin wrench -T10020- on eccentric to left (direction of arrow) until indicator -2- is above notch -1- (toothed belt over-tensioned).
  Note
Repeat this work step (over-tension toothed belt) 5 times so that the toothed belt settles.
–  Now reduce tension on toothed belt until notch -1- and indicator -2- align.
–  Tighten securing nut to 20 Nm.
–  Turn crankshaft 2 revolutions in direction of engine 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 toothed belt tension again. Specification: pointer and notch align.
–  Check valve timing again.
If marks do not align
–  Repeat valve timing adjustment.
–  Attach engine bracket to cylinder block from above and tighten both upper bolts to 45 Nm.
–  Lower engine to installation position.
–  Install lower bolt and tighten to 45 Nm.
–  Install complete engine assembly mounting. Torque settings → Chapter.
  N13-0402
–  Bolt engine assembly mounting to engine bracket -arrows- by bringing contact surfaces together using support bracket -10-222A-. Specified torque: 60 Nm + 90° turn further.
–  Remove support bracket 10-222 A.
–  Install toothed belt guard upper part.
–  Install poly V-belt → Chapter.
–  Install coolant expansion tank.
–  Install noise insulation → General body repairs, exterior; Rep. Gr.50.
–  Fit engine cover.
  N10-0437

Checking semi-automatic toothed belt tensioner > < Removing toothed belt