Late Version

TOOTHED BELT IN VEHICLES WITH NEW 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

Note: The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. While doing this, tensioner must have a temperature of at least 30°C, otherwise it cannot be compressed further.

^ Coolant Temperature at least 30°C.

- 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.




- Turn toothed belt tensioning roller -1- in direction of arrow using a hex socket wrench (8 mm) and extension (e.g. V.A.G 3114) until holes of piston and tensioner housing overlap and securing pin (e.g. cotter pin with 1.5 mm dia.) can be slid into hole - 2-.

Note: Bolt -3- must not be loosened.

- 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. Valves and/or pistons may be damaged.




- 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.




- Tension toothed belt, to do so, turn toothed belt tensioning roller -1- in direction of arrow using a hex socket (8mm) and extension (e.g. V.A.G 3114) until securing pin can be pulled out.

Note: Bolt -3- must not be loosened.

- Then turn tensioning roller in opposite direction of arrow until piston is completely driven out (use mirror).
- Turn crankshaft twice and check whether camshaft and crankshaft markings align properly with their respective points.
- Remove harmonic balancer/belt pulley.
- Install lower portion of toothed belt guard.
- Install harmonic balancer and belt pulley.
Tightening torque: 25 Nm
- Install upper portion of toothed belt guard.
- Install tensioner for ribbed belt.
Tightening torque: 25 Nm
- Install ribbed 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.




- Tension toothed belt, to do so, turn toothed belt tensioning roller -1- in direction of arrow using a hex socket (8mm) and extension (e.g. V.A.G 3114) until securing pin can be pulled out.

Note: Bolt -3- must not be loosened.

- Then turn tensioning roller in opposite direction of arrow until piston is completely driven out (use mirror).
- Turn crankshaft twice and check whether camshaft and crankshaft markings align properly with their respective points.
- Install upper portion of toothed belt guard.
- Install tensioner for ribbed belt.
Tightening torque: 25 Nm
- Install ribbed belt.