- Remove the timing belt cover or covers.
- Loosen the generator fastenings by moving it towards the center, remove the V-belt.
- Remove the valve cover.
- Install a special control plate (No. 2065 A) on the cylinder head from the flywheel side (figure 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 coincides with the mark in the control hole (after removing the plug from the wall of the gearbox housing), as shown in Figure 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 cylinder head.
- At the opposite end of the plate, measure the gap between the cylinder head and the plate.
- Place a feeler gauge under the plate that is half the thickness of the measured gap.
- Turn the camshaft so that the plate rests on the feeler gauge.
- Insert a second feeler gauge of the same thickness on the other side between the cylinder head and the plate.
To perform the following operations, a special rod No.2064 is required, which is screwed into the toothed pulley of the fuel injection pump to block its rotation (figure 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 it is necessary to remove the rear timing belt cover (see figure 214), it is necessary to remove the fuel injection pump bracket. If necessary, unscrew the bolts securing the toothed pulley of the camshaft. 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.
Installing a timing belt (for example after replacing it) is performed in the following order:
- First, make sure the flywheel is in the position shown in Figure 216.
- Loosen the camshaft toothed pulley mounting bolts by half a turn (without turning the shaft itself). Hit the pulley with a rubber mallet to loosen its boss on the shaft cone. In the case of an engine with a closed belt cover, it is necessary to hit it in the place shown by the arrow on figure 214, insert the rod and hit it with a hammer, loosening the pulley boss on the shaft cone.
[The information is available on the website www.VWmanual.ru]
Carefully lay the timing belt and remove the mounting rod from the pump pulley.
Using the special tool VW 21O, check the tension of the timing belt (figure 218). Place the device between the camshaft and pump pulleys, and then, turning the tensioner to the right, set the belt tension value to 12-13 units on the device scale. There are special protrusions for turning the tensioner, shown by the arrow in Figure 218. You can also try to turn the tensioner roller by hand.
Tighten the tensioner mounting nuts to a torque of 45 Nm. Tighten the camshaft pulley mounting bolts to the same torque. Install all parts and assemblies in place. Rotate the pulley to turn the crankshaft two full revolutions.
Use a rubber mallet to strike the timing belt where the belt tensioner was installed.
After installing and adjusting the belt tension, you need to check the fuel pump installation using the following method, described here.
Install the V-belt pulley onto the crankshaft toothed pulley. Tighten its mounting bolts to 20 Nm. Support the flywheel while doing this. Install the toothed belt cover or covers.
Install the V-belt and adjust its tension.
Adjust the valve clearances (see here), if the engine was manufactured before 1986.
Visitor comments