2. You can turn the engine crankshaft in the following ways:
- raise the front of the car and secure it on stands. Put it in 5th gear and apply the handbrake. While holding one front wheel from turning, manually turn the other front wheel. This will cause the engine crankshaft to turn;
- place the car on a flat horizontal surface, then engage 5th gear and manually move the car forward or backward;
- set the gearbox to neutral and apply the handbrake. Using a wrench, turn the engine crankshaft by the crankshaft pulley mounting bolt.
Warning: Do not turn the engine crankshaft by the camshaft pulley mounting bolt, as this will place maximum load on the timing belt.
Manual transmission
3. Remove the plug in the clutch housing.
4. Turn the engine crankshaft until the "0" mark on the flywheel aligns with the pointer on the clutch housing (arrow). When the marks align with the pointers, the piston of the first cylinder is at TDC in the compression stroke (A - AGP engine, B - AGR, AHF, ALH engines).
Automatic transmission
5. Turn the engine crankshaft until the "0" mark appears on the left in the torque converter window (arrow). In this case, the piston of the first cylinder is at TDC in the compression stroke.
SDI diesel engine
6. Remove the intake manifold.
7. Remove the upper timing belt cover and cylinder head cover.
8. If the timing belt is to be reinstalled, use a marker or paint to mark the direction of rotation of the timing belt. When viewed from the front of the engine, the engine pulleys rotate clockwise.
(View the original on this portal www.vwmanual.ru)
9. Unscrew the bolts (indicated by arrows), securing the expansion tank and the power steering refill tank and, without disconnecting the hoses from them, move them to the side.
10. Install locking tool 3418 into the groove in the end of the camshaft.
11. With the locking tool installed in the camshaft, turn the camshaft (turning the crankshaft clockwise) so that one side of the locking tool is pressed against the surface of the cylinder head. Using the blade of the feeler gauge, measure the gap between the other end of the locking tool and the cylinder head. Turn the camshaft slightly back and install two feeler gauges on both sides between the locking tool and the cylinder head, the thickness of which is equal to half the previously measured gap.
12. Lock the fuel pump pulley with the VW-3359 locking pin. Unscrew the bolts (1) from the fuel pump pulley and screw in new bolts in their place, tightening them by hand at this stage. Unscrew the bolts one by one, since the fuel pump pulley sections may shift. Do not unscrew the central nut (2) securing the fuel pump pulley, since this may cause the pulley to shift.
13. Since the right support of the power unit prevents the removal of the toothed belt, it is necessary to support the engine with a special device VW 10-222A and remove the right support of the power unit.
14. The engine can be supported from below using a jack through a wooden block.
15. While holding the crankshaft pulley from turning, unscrew the four bolts securing the pulley to the crankshaft. Remove the crankshaft pulley.
16. Unscrew the bolts (indicated by arrows), fastening the right support of the power unit to the body and the engine mount.
17. Unscrew the bolts (indicated by arrows), securing the right powertrain support bracket to the engine.
18. Unscrew the timing belt tension roller mounting nut.
19. Remove the timing belt from the engine pulleys.
Warning: Do not sharply bend the toothed belt, as during operation the toothed belt may break at the sharp bend, which will lead to engine damage.
20. After removing the timing belt, do not change the position of the timing belt pulleys.
Warning: If the engine crankshaft is turned after the timing belt is removed, the pistons will collide with the valves, causing damage to the valves and requiring major engine repairs. Mark the position of the crankshaft pulley by making marks on the pulley and engine block with paint. If necessary, the engine crankshaft can be turned 90° clockwise or counterclockwise.
Warning: Check the timing belt for wear, delamination or oil contamination. If there is oil on the timing belt, find the source of the oil leak and repair it before installing a new belt.
Warning: Do not twist or bend the timing belt. Do not allow oil, coolant or fuel to come into contact with the timing belt.
Visitor comments