- Remove the toothed belt guard or guards.
- Loosen the alternator mountings by moving it to the center, remove the V-belt.
- Remove the valve cover.
- Special control plate (№2065 A) install on the head of the block from the side of the flywheel (pic. 215), after setting the piston of the 1st cylinder to the TDC position. Then turn the crankshaft so that the control mark on the flywheel matches the mark in the control hole (after removing the plug from the wall of the gearbox housing), as shown in fig. 216.
Install the control plate as follows:
- Install it by rotating the camshaft until one end of the plate rests against the surface of the block head.
- At the opposite end of the plate, measure the gap between the block head and the plate.
- Insert a feeler gauge half the measured gap under the plate.
- Turn the camshaft so that the plate rests on the dipstick.
- Insert a second feeler gauge of the same thickness on the other side between the block head and the plate.
To perform subsequent operations, a special rod No. 2064 is required, which is screwed into the gear pulley of the injection pump to block its rotation (pic. 217).
Loosen the tensioner nuts and move it to the left, remove the pulley from the crankshaft and the toothed belt from the toothed pulleys.
If necessary, remove the rear toothed belt cover (see fig. 214), it is necessary to remove the injection pump bracket. If required, remove the camshaft sprocket bolts. To remove the pulley from the shaft, insert a small rod into the hole shown by the arrow and hit it with a hammer, thus loosening the fastening of the pulley boss on the cone.
Timing belt installation (e.g. after replacing) is done in the following order:
- First, make sure the flywheel is in the position shown in fig. 216.
- Loosen the camshaft sprocket bolts by half a turn (without turning the shaft). Hit the pulley with a rubber mallet to loosen its boss on the shaft taper. In the version of the engine with a closed belt cover, it is necessary to the place shown by the arrow on rice. 214, insert the rod and hit it with a hammer, loosening the fastening of the pulley boss on the shaft cone.
Place the toothed belt carefully and remove the adjusting rod from the pump pulley.
Using the special tool VW 21O, check the tension of the toothed belt (pic. 218). Place the device between the camshaft and pump pulleys, and then, turning the tensioner to the right, set the belt tension to 12-13 units. according to the adjustment scale. To rotate the tensioner, special protrusions are provided, shown by the arrow in fig. 218. You can also try turning the tensioner roller by hand.
Tighten the tensioner mounting nuts to a torque of 45 Nm. Tighten the camshaft pulley bolts to the same torque. Reinstall all parts and assemblies. Rotate the pulley to rotate the crankshaft two full turns.
With a rubber mallet, hit the toothed belt at the point where the belt tensioner was installed.
After installing and adjusting the belt tension, you need to check the installation of the high-pressure fuel pump in the way described here.
Install the V-belt pulley on the crankshaft sprocket. Tighten its fastening bolts with a torque of 20 Nm. In this case, you need to support the flywheel. Install the toothed belt guard or guards.
Install the V-belt and adjust its tension.
Adjust valve clearances (see here), if the engine was manufactured before 1986.
Visitor comments