Toothed Belt, Removing, Installing and Tensioning

Toothed belt, removing, installing and tensioning





Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ For tensioner up to 07.00 (fixed):
^ Tensioning bolt T10092
^ Pin T40011
^ For tensioner from 08.00 (adjustable):
^ Pin wrench 3387
^ Locking plate T10008

Removing
- Bring the lock carrier into service position. [1][2]Procedures
- Remove ribbed belt.
- Remove ribbed belt tensioner.
- Remove upper toothed belt guard.
- Mark direction of rotation of toothed belt.





- Turn crankshaft to set cylinder 1 at TDC.





- Remove harmonic balancer/belt pulley.
- Remove lower and middle toothed belt cover.

Tensioner up to 07.00 (not adjustable)





- Thread tensioning bolt T10092 into toothed belt tensioner.
- If necessary, align pressure piston before tensioning using needle nose pliers or a thin wire (hole in pressure piston and hole in housing must line up).
- Tighten the tensioner pressure piston just enough so that the pressure piston can be secured using pin T40011.

For tensioner roller from 08.00 (must be adjusted)





- Insert hex wrench into socket-head up to stop and apply slow, steady, counterclockwise pressure direction of - arrow -, until tensioner can be locked in place using locking plate T10008.

Note: The toothed belt tensioner is oil-dampened and can only be compressed slowly and by applying constant pressure. Applying excessive force may damage the tensioner.





- To release tension on toothed belt, loosen the bolt - 1 - of tensioner and rotate eccentric using pin wrench 3387 in direction of - arrow -.

Note: Stop tab - A - of eccentric must not be bent.

Continued for all vehicles
- Remove toothed belt.
- Turn crankshaft back slightly.

Installing

Conditions
^ The pistons must not be positioned at TDC when turning the camshaft.

Work procedure





- Align marking on camshaft sprocket with marking on cylinder head cover.
- Place toothed belt onto crankshaft sprocket (observe direction of rotation).
- Install toothed belt cover - lower part.





- Install harmonic balancer/belt pulley with new bolts.
- Tightening torque: 10 Nm plus 1/4 turn (90°)





- Turn crankshaft to set cylinder 1 at TDC.
- Place toothed belt on coolant pump, tensioner roller and camshaft gear (in this order).
- Tension toothed belt.

Toothed belt, tensioning

Requirements
^ The engine must be no more than warm to touch.
^ Cylinder 1 at TDC.

Procedure

Tensioner up to 07.00 (not adjustable)





- Tension toothed belt by removing pin T40011 and removing tensioning bolt T10092.

Tensioner from 08.00 (must be adjusted)

Note: If toothed belt tensioner is completely extended, it must be retracted manually to the installation position. This procedure may take up to 5 minutes. Applying excessive force may damage the tensioner.





- Turn eccentric pulley counterclockwise using pin wrench 3387 (tab - A - of eccentric pulley must not be bent), until locking plate T10008 can be removed without tension.





- Rotate eccentric pulley clockwise in direction of - arrow - until a drill bit - 2 - with dimension - a - can be pulled through between tensioning lever and tensioner housing.
- Specified dimension - a - : 8 mm
- Hold tensioner roller in this position and tighten securing nut - 1 - with tensioner roller to 27 Nm.

Continued for all vehicles





- Turn over crankshaft twice and check if markings on camshaft and crankshaft still align with their reference points.

Tensioner roller from 08.00 (must be adjusted)





- Check dimension - a - between tensioning lever and tensioner housing using a drill bit - 2 -.
- Specified dimension - a - : 6 to 10 mm

If dimension - a - is not obtained:
- Release tension of toothed belt and tension it again.

If dimension - a - is obtained:

Continued for all vehicles
- Install center and upper toothed belt covers.
- Install ribbed belt tensioner.
- Tightening torque: 25 Nm
- Install ribbed belt.