Timing belt drive with single pulley injection pump

Removing

1. Remove the ribbed belt.

2. Remove the ribbed belt tensioner, if installed.

3. Remove the upper part of the timing case and the cylinder head cover.

4. Align the TDC marks of the piston of cylinder No. 1 on the crankshaft: A - AEY, ANV, AKW engines, B - AFN, AHU, ALE engines (pic. 6.3).

Engines AEY, ANV, AKW

5. Install adjuster 2068 A as shown in fig. 6.4. Set the adjusting device to 5mm (arrow A). Turn the crankshaft so that the TDC marks on the flywheel match the mark on the setting device (arrow B).

AFN, AHU, ALE engines

6. Install adjuster 2068 A as shown in fig. 6.5. Set the adjuster to 96.0 mm. The reference point is the graduated mark on the left side of the vernier (arrow A) Turn the crankshaft so that the TDC marks on the flywheel match the mark on the setting device (arrow B).

For all engines

7. Lock the camshaft pulley with the lock (pic. 6.6).



8. Lock the injection pump pulley with the locking pin (pic. 6.7).



9. Loosen the tension roller.

10. Remove the coolant pump pulley (use VAG 1590 to loosen and tighten the fixing bolt).

11. Remove the crankshaft pulley/damper.


12. Remove the lower part of the timing belt cover.

13. Mark the direction of movement of the timing belt.

14. Remove the intermediate roller.

15. Remove the timing belt.

Installation

16. Make sure that the TDC mark on the flywheel and the reference point are aligned.

17. Loosen the camshaft pulley bolt 1/2 turn (pic. 6.8). Disconnect the pulley from the hub using a hammer and punch.



18. Install the timing belt in the direction of travel and remove the injection pump pulley locking pin.

19. Install the intermediate roller. Tightening torque - 25 Nm.

20. Tighten the timing belt (pic. 6.9). Using a wrench, turn the tension roller in the direction of the arrow (clockwise) so that the marks (arrows) aligned.



21. Tighten the idler pulley lock nut. Tightening torque - 20 Nm.


22. Make sure again that the TDC mark on the flywheel and the reference point are aligned.

23. Tighten the camshaft pulley bolt to 45 Nm.

24. Remove the camshaft pulley retainer.

25. Scroll the crankshaft two turns in the direction of rotation so that the TDC marks on the crankshaft are aligned.

26. Check the alignment of the TDC marks on the flywheel, check the blocking of the camshaft pulley with a lock, check the blocking of the injection pump pulley, check the installation and ease of rotation of the tension roller.

27. If the marks are not aligned, pull the tension roller with a wrench, loosening the fixing nut, turn the eccentric clockwise so that the marks are aligned, and tighten the nut to 45 Nm.

28. Scroll the crankshaft two turns in the direction of rotation so that the TDC marks on the crankshaft are aligned.

29. Repeat checks.

30. Install the timing belt housing parts, damper and cylinder head cover.

31. Install the ribbed belt.

32. Check up giving TNVD.