Removing, Installing and Tensioning Toothed Belt: Special Tools and Workshop Equipment Required

Removing, installing and tensioning toothed belt
Special tools and workshop equipment required

 Torque wrench -V.A.G 1331-
 Pin wrench -3387-
 Locking plate -T10008-
 Torque wrench -V.A.G 1332-

Removing
Move lock carrier to service
–
position → Chapter.
Release quick fasteners -arrows-
–
and remove engine cover panel.
Note
Before removing, mark direction of

rotation of poly V-belt with chalk or
felt-tip pen. If the belt runs in the
opposite direction when it is refitted,
this can cause breakage.
Turn the tensioner in the direction
– of the -arrow- to slacken the poly
V-belt.
– Remove poly V-belt.
Unscrew bolts -arrows- and

–
remove poly V-belt tensioner.
– Remove toothed belt cover (top).
Rotate crankshaft to TDC by
– turning bolt for toothed belt
sprocket.
Caution
The engine must only be turned at
the crankshaft, in the direction of
normal engine rotation (clockwise).
Marking on camshaft sprocket and
 marking on crankshaft must be
aligned to TDC -arrows-.
Counterhold by applying ring

spanner to bolt for toothed belt
–
sprocket and unbolt vibration
damper.
Remove toothed belt cover (centre
–
and bottom) -arrows-.
With hydraulic tensioning roller
Caution
The toothed belt tensioner is oil-
damped and can therefore only

be compressed slowly by
applying constant pressure.
To avoid damage, do not apply
more force than necessary when

compressing the toothed belt
tensioner.
Applying constant and moderate

force, use hexagon key to press
toothed belt tensioner anti-
–
clockwise in direction of -arrow-
until piston of tensioner can be
locked with locking plate -T10008-.
Insert locking plate -T10008- and
–
make sure that it remains in place.
Note
Do not to bend limit stop -A- of

eccentric adjuster.
To slacken toothed belt, loosen nut
-1- on tensioning roller and turn
–
eccentric adjuster clockwise
-arrow- using pin wrench -3387-.
Without hydraulic tensioning roller
Loosen nut -1- to slacken toothed
–
belt.
All models:
Mark direction of rotation of
– toothed belt with chalk or felt-tip
pen.
– Remove toothed belt.
Installing (adjusting valve timing)
Note
The toothed belt adjustment must
also be performed as described
 below, even if the toothed belt has
only been removed from the
camshaft sprocket.
The crankshaft must not be at
TDC at any cylinder when the
 camshaft is turned. Otherwise,
there is a risk of damage to valves
and piston crowns.
Fit toothed belt on crankshaft
–
sprocket (note rotation direction).
– Install bottom toothed belt cover.
Note
The vibration damper/ pulley can only
be installed in one position: The hole
-arrow- in the vibration damper must
fit over the projection on the toothed
belt sprocket on the crankshaft.
Secure vibration damper/ pulley.
–
Note positive location -arrow-.
Align markings on camshaft
sprocket / cylinder head cover and
–
markings on vibration damper /
toothed belt cover -arrows-.
Make sure that toothed belt
– tensioner is still locked with locking
plate -T10008-.
All models:
Fit toothed belt onto coolant pump,
– then tensioning roller, and finally
camshaft sprocket.
Tensioning toothed belt
Note
Do not to bend limit stop -A- of
eccentric adjuster.
Turn eccentric adjuster anti-

– clockwise onto stop in direction of
-arrow- using pin wrench -3387-.
Hold eccentric adjuster in this
– position and pull out locking plate
-T10008-.
Turn eccentric adjuster clockwise
in direction of -arrow- until gauge
-2- with dimension -a- = 8 mm (e.g.
–
drill bit) can be pulled through
between tensioning lever and
housing of tensioner.
Hold eccentric adjuster in this
– position and tighten nut -1- of
tensioning roller to 27 Nm.
Caution
Turn crankshaft two rotations via

– toothed belt sprocket bolt until it is
positioned at TDC again.
Use gauge -2- (e.g. drill bit) to
check dimension -a- between
–
tensioning lever and housing of
tensioner.
 Dimension -a- = 6 ... 10 mm.
If dimension -a- is achieved, see
"Assembling" → Anchor.
If dimension -a- is not attained:
Caution
The toothed belt tensioner is oil-
damped and can therefore only

be compressed slowly by
applying constant pressure.
To avoid damage, do not apply
more force than necessary when

compressing the toothed belt
tensioner.
Applying constant and moderate
force, use hexagon key to press
toothed belt tensioner anti-
–
clockwise in direction of -arrow-
until piston of tensioner can be
locked with locking plate -T10008-.
– Loosen nut -1- for tensioning roller.

– Tension toothed belt → Anchor.
Without hydraulic tensioning roller
Retaining lug -arrow- must engage

in slot on cylinder head.
Use a hexagon key to turn toothed

belt tensioning roller in direction of
–
-arrow- until dimension -a- is
attained.
 Dimension -a- = 5 - 8 mm.
Turn back toothed belt tensioning
– roller, but do not slacken
completely.
Turn toothed belt tensioning roller
in direction of -arrow- using a
–
hexagon key until markings -1 and
2- are aligned.
Tighten nut -3- for tensioning
–
roller.
Note
Marking -1- (right edge of projection)
must coincide with marking -2-.
Caution
Turn crankshaft two rotations via

– toothed belt sprocket bolt until it is
positioned at TDC again.
Check toothed belt tension:
marking -1- must be between
–
markings -arrows-; correct tension
if necessary.
Assembling
Fit centre and top section of
–
toothed belt cover.
Installation is carried out in the
reverse order; note the following:
Install poly V-belt tensioner
–
-arrows-.
– Install poly V-belt → Chapter.
Install top section of toothed belt
cover (make sure it engages
–
securely on centre section of
toothed belt cover).
Install lock carrier with

– attachments →General body
repairs, exterior; Rep. gr.50.
Allow stop for torque reaction
support to rest on rubber buffer for
– torque reaction support under its
own weight and tighten nuts
-arrows-.
Install front bumper cover
– →General body repairs,
exterior; Rep. gr.63.
– Check headlight adjustment → .
Tightening torques
Component Nm
Tensioning roller to cylinder head 27
Vibration damper to toothed belt sprocket 10 + 90° → Remark → Remark
Toothed belt cover (bottom and centre section) to cylinder block 10 → Remark
Tensioner for poly V-belt to bracket for ancillaries 23
Stop for torque reaction support to lock carrier 28
1)
Install using locking fluid → Parts catalogue
2)
Renew bolts.
3)
90° equals a 1/4 turn.

Removing, Installing and Tensioning Toothed Belt: Special Tools and Workshop Equipment Required

Uploaded by

Copyright:

Available Formats

Removing, Installing and Tensioning Toothed Belt: Special Tools and Workshop Equipment Required

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Removing, Installing and Tensioning Toothed Belt: Special Tools and Workshop Equipment Required

Uploaded by

Copyright:

Available Formats

Removing, installing and tensioning toothed belt

Special tools and workshop equipment required

Before removing, mark direction of

Unscrew bolts -arrows- and

Counterhold by applying ring

Applying constant and moderate

Do not to bend limit stop -A- of

Turn eccentric adjuster anti-

Turn crankshaft two rotations via

– Loosen nut -1- for tensioning roller.

Use a hexagon key to turn toothed

Turn crankshaft two rotations via

Install lock carrier with

Vibration damper to toothed belt sprocket 10 + 90° → Remark → Remark

Tensioner for poly V-belt to bracket for ancillaries 23

Stop for torque reaction support to lock carrier 28

You might also like