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Home >> Volkswagen >> 2005 >> Passat Wagon (3B6) L4-2.0L DSL Turbo (BHW) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Timing Belt >> Service and Repair >> Procedures >> Toothed Belt, Removing, Installing and Tensioning

Toothed Belt, Removing, Installing and Tensioning




Toothed Belt, Removing, Installing, and Tensioning






Special tools, testers and auxiliary items required

- Rig pin 3359
- Pin wrench 3387
- Crankshaft stop T10050
- Pin T10115
- Torque wrench (5 to 50 Nm) V.A.G 1331
- Torque wrench (40 to 200 Nm) V.A.G 1332

Removing

Note:
- Adjustments to the toothed belt may generally only be performed when the engine is cold.

- Bring lock carrier into service position. [1][2]Procedures
- Remove ribbed belt.
- Remove upper toothed belt guard.
- Remove fan wheel from viscous fan clutch.
- Unscrew ribbed belt relay lever from bracket.
- Remove center toothed belt guard.
- Remove harmonic balancer/belt pulley.
- Remove lower toothed belt guard.
- Turn crankshaft to set cylinder 1 at TDC.






Note:
- Turn the crankshaft so far that the marking on the toothed belt crankshaft sprocket is positioned on top and the arrow on the rear toothed belt guard is positioned across from the tabs of the sensor wheel on the hub.

- Lock hub with rig pin 3359. To do this, push rig pin through left-sided empty slot in bore of cylinder head.
- Also, lock toothed belt crankshaft sprocket with crankshaft stop T10050. Push crankshaft stop from front side of toothed belt sprocket into teeth.

Note:
- Markings on toothed belt crankshaft sprocket and the crankshaft stop must be aligned. The tab of the crankshaft stop must engage in the bore of the sealing flange.

- Mark direction of rotation of toothed belt.
- Loosen nut of tensioning roller.






- Loosen bolts -1- of camshaft sprockets, until camshaft sprocket can be turned in slots.






- Turn pin wrench 3387 counter-clockwise (against direction of arrow) until toothed belt tensioning roller can be locked with pin T10115.
- Turn pin wrench in direction of arrow on roller until stop and then tighten nut by hand.
- First, take toothed belt from coolant pump and then from remaining sprockets.

Installing

Caution!
- When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.

Requirements
- Hub locked with rig pin 3359.
- Crankshaft locked with crankshaft stop T10050.
- Tensioning roller secured with pin T10115 and seated on right stop.

Note:
- Adjustments to toothed belt may generally only be performed when the engine is cold, because the indicator position of the tensioning element changes depending on engine temperature.






- Turn camshaft sprocket counter-clockwise in its slots direction of -arrow- onto stop.
- Lay toothed belt on crankshaft sprocket, tensioning roller and camshaft sprocket.
- Lastly, lay toothed belt onto toothed belt coolant pump sprocket.






Note:
- Make sure the tensioning roller is properly positioned at the rear toothed belt guard -arrow-.

- Loosen nut of tension roller.
- Tension tensioning roller by turning nut against direction of arrow and removing pin.






- Carefully turn tensioning roller with pin wrench 3387 in direction of arrow, until indicator is located centrally in gap of base plate -arrow-.
- Hold tensioning roller in this position and tighten tensioning roller nut: Tightening torque 20 Nm plus and additional 45°(1/8 turn).
- Tighten camshaft sprocket bolts to 25 Nm.
- Remove the rig pin 3359 and the crankshaft stop T10050.
- Turn crankshaft over twice in engine running direction and then set cyl. 1 to TDC again.

Note:
- The tab of the crankshaft stop must engage in the sealing flange when turning engine over.
- If the crankshaft was turned past TDC for cylinder 1 and if the crankshaft stop could not engage the sealing flange, turn the crankshaft back 1/4 revolution in order to turn the crankshaft in the engine running direction again to TDC for cylinder 1. It is not reliable to correct this by turning the engine against the running direction to set the crankshaft stop.

- After crankshaft stop has been set, check that hub can be locked with rig pin 3359.

If the hub cannot be locked:

- Pull crankshaft stop tab out of bore in sealing flange and turn crankshaft until hub can be locked with rig pin.







- Loosen camshaft sprocket bolts -1-.








- Turn crankshaft against engine running direction until crankshaft stop tab is positioned shortly before sealing flange bore -arrow-.
- Turn crankshaft in engine running direction until crankshaft stop tab engages sealing flange.
- Tighten camshaft sprocket bolts to 25Nm.
- Remove rig pin 3359 and the crankshaft stop T10050.
- Turn crankshaft twice in engine running direction until crankshaft is at TDC for cylinder 1 again.

Note:
- The tab of the crankshaft stop must engage in the sealing flange when turning engine over.
- If the crankshaft was turned past TDC for cylinder 1 and if the crankshaft stop could not engage the sealing flange, turn the crankshaft back 1/4 revolution in order to turn the crankshaft in the engine running direction again to TDC for cylinder 1. It is not reliable to correct this by turning the engine against the running direction to set the crankshaft stop.

- Check again.
- Install lower toothed belt guard and harmonic balancer/belt pulley.
- Install center toothed belt guard.
- Fasten ribbed belt relay lever to bracket.
- Install ribbed belt.
- Install fan wheel to viscous fan clutch.
- Install lock carrier.


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