Removal and installation of a gear belt (diesel 5-cylinder)

Removing

1. Place the machine on stands.

2. Remove the lower engine compartment cover.

3. Swing the radiator and lock support forward.

4. Remove the alternator and power steering pump V-belts (see subsection 2.12.1 and subsection 2.12.2).

5. Swing the alternator all the way up and tighten the bolts securely.

6. Unscrew the cylinder head cover, remove the sealing and cup washers.

7. Unscrew the rear guard of the injection pump drive from the cylinder head.

8. Loosen the clamps and remove the air hose between the air filter and the intake manifold.

9. Open the locks and remove the front camshaft drive guard.

10. Apply with a felt-tip pen or grease pencil on the toothed belt an arrow indicating the direction of its movement. The direction of rotation of the engine, when viewed from the side of the toothed belt, is right-hand, clockwise.

11. Set the crankshaft to TDC for cylinder 1.

12. The crankshaft is in the TDC position for 1 cylinder if the marks on the flywheel-clutch housing match.


13. At the same time, the marks on the injection pump gear and the console must match (indicated by arrows). If the marks do not match, rotate the crankshaft one revolution in the direction of rotation.




14. Seal the injection pump gear with a suitable pin, VW-2064 or pin, as shown in the figure.



15. Hold the injection pump drive gear with a VW-3036 counterholder. Unscrew the mounting bolt, remove the drive gear and the injection pump timing belt.



16. Seal the camshaft with the VW-2065-A setting ruler. If there is no special tool at hand, make a ruler, as shown in the figure Adjusting ruler and mandrel for checking the camshaft. The setting ruler has a notch that prevents the camshaft from turning.


17. Take the car off the stand.



18. Unscrew the center bolt of the crankshaft vibration damper. This requires a VW-3248 counterholder. Due to the high torque when unscrewing the bolt, the machine must be on wheels.

19. Place the machine on stands.

20. Unscrew the M8 bolt from the vibration damper.

21. Remove vibration damper.

22. Loosen the water pump bolts and loosen the toothed belt.

23. Unscrew bottom toothed belt guard.

24. Remove toothed belt from crankshaft gear.

Attention! The toothed belt must not have cuts. A belt with cuts must be replaced without fail, as it may break during operation, which will lead to severe engine damage.

Attention! If the camshaft rotates with the toothed belt removed, neither piston should be at TDC. Otherwise, serious damage to pistons or valves cannot be avoided.

Attention! If you need to rotate the shaft, then first set all pistons at the same height. To do this, put a chalk mark on top of the crankshaft pulley (precondition: crankshaft is in TDC position for 1 cylinder), then turn the crankshaft pulley 1/4 turn to the left or right. The chalk mark should now point to the left or right.

Installation

1. Through the viewing window in the gearbox, check the coincidence of the TDC mark on the flywheel with the corresponding mark.

2. Seal the camshaft with a setting ruler.

3. Balance the setting bar: To do this, turn the jammed camshaft so that one end of the setting bar rests on the cylinder head. Under the other end of the ruler, measure the resulting gap with a petal probe. Insert a probe equal to half the measured size between the end of the ruler and the head of the block. Rotate the camshaft so that the end of the ruler rests on the dipstick. Insert the second petal probe of the same size under the other end of the ruler - between the ruler and the head of the block.

4. Loosen the camshaft drive gear bolt 1/2 turn.

5. Knock off the camshaft drive gear from the camshaft cone by hitting the spike inserted into the 6 mm hole in the toothed belt housing with a hammer.

6. Fit the camshaft toothed belt.

Attention! If an old belt is to be used, be sure to pay attention to the direction of its movement. Installing the belt in the opposite direction can cause it to break and damage the engine. Therefore, always install the belt so that the marked arrow indicates the direction of rotation of the engine (when viewed from the side of the toothed belt, then clockwise).

7. Install the lower toothed belt cover.

8. Pull on toothed belt.

9. Tighten the lower toothed belt cover.

10. Check if the crankshaft is in the TDC position for 1 cylinder, install if necessary.


11. Tighten the camshaft drive gear bolt to 85 Nm.

12. Remove setting line.

13. Put on vibration damper and tighten 4 M8 bolts to 20 Nm.

14. Take the car off the stand.

15. Install the vibration damper center bolt. Preliminarily apply sealant AMV18800102 to the thread and the contact surface of the head.

16. Tighten the central bolt to 460 Nm.

Attention! Due to the high tightening torque, the machine must be on wheels.

17. Remove counterholder VW-3248.



18. Install drive gear and injection pump timing belt.

19. Tighten the pinion bolt to approx. 50 Nm, then loosen it by 1/2 turn. The drive gear must rotate by hand.

20. Check the tension of the rear toothed belt with the control device VW-210. Required value: 12...13 of the instrument scale.



21. If necessary, adjust the tension of the rear toothed belt. To do this, loosen the mounting bolts (arrows) and move the console from the injection pump down or up.

22. Tighten bolts on console to 50 Nm.

23. Remove the spike from the injection pump gear.

24. Check and adjust the start of the injection pump fuel supply (see subsection 2.17.7.6).

25. Screw on the injection pump drive cover.

26. Check cylinder head cover gasket, replace if necessary. Check the presence of the sealing cone on the stud, install if necessary. Install the gasket, install the cylinder head cover, fit the top sealing washer and Belleville washer onto the stud. Tighten the two nuts to 10 Nm, put on the sealing caps.

27. Install the top toothed belt guard from the front.

28. Put on and tighten the V-belt (see subsection 2.12.1).

29. Install the air hose between the air filter and intake pipe and secure with two clamps.

30. Install the radiator with lock support.

31. Place the machine on stands.

32. Install the lower engine cover.

33. Take the car off the stands.