Early Version

TOOTHED BELT IN VEHICLES WITH OLD TOOTHED BELT TENSIONING SYSTEM, REMOVING









Special tools, testers and auxiliary items required
^ Pin wrench V/59
^ Torque wrench 5-50 Nm V.A.G 1331
^ Door alignment device 3114

- Bring lock carrier into service position. Refer to Body and Frame - Service and Repair - Procedures - Lock Carrier, Removing and Installing [1][2]Procedures
- Remove ribbed belt. Refer to Drive Belts, Mounts and Accessories - Ribbed Belt - Service and Repair - Procedures [1][2]Procedures
- Remove ribbed belt tensioner.




- Set crankshaft to TDC Cylinder 1.
- Remove upper portion of toothed belt guard.
- Mark rotational direction of toothed belt.




- Remove harmonic balancer/belt pulley.
- Remove lower toothed belt guard.




- Loosen toothed belt tensioner - arrow - and remove toothed belt.
- Turn crankshaft back slightly.

TOOTHED BELT, INSTALLING COMPLETELY

A. If toothed belt was only removed from camshaft gear

Note: When turning camshaft, crankshaft may not be at TDC for any cylinder. Danger of damage valves/piston crown.




- Align marking on camshaft gear with marking on cylinder head cover.
- Set toothed belt on crankshaft gear (watch direction of rotation).
- Using a bolt, secure harmonic balancer/belt pulley (watch locating point).





- Set crankshaft to TDC Cylinder 1.
- Lay toothed belt on tensioner and camshaft gear.

- Go to C. Tensioning toothed belt.

B. If toothed belt was removed completely




- Align marking on camshaft gear with marking on cylinder head cover.
- Set crankshaft to TDC Cylinder 1.
- Install toothed belt on camshaft gear.

- Go to C. Tensioning toothed belt.

C. Tensioning toothed belt




- Tension toothed belt, to do so turn tensioner -A- toward right using pin wrench -B- (e.g. Matra V159) until piston -1- is driven out completely and piston lifts tensioner -2- approx. 1 mm.
- Tighten securing bolt -3- on tensioning roller.
Tightening torque: 25 Nm
- Turn crankshaft twice and check whether camshaft and crankshaft markings align properly with their respective points.




- Check whether area -A- aligns with upper edge of piston or dimension -D- is 25 - 29 mm.

Note:

^ Area - A - : Adjustment OK.
^ Area - B - : Wear range
^ Area - C - : Check belt drive and tensioning roller for wear/adjust toothed belt tension.

- Install upper portion of toothed belt guard.
- Install ribbed belt tensioner.
Tightening torque: 25 Nm
- Install ribbed belt.