2. You can turn the crankshaft of the engine in the following ways:
- Raise the front of the car and secure it on stands. Engage 5th gear and apply the handbrake. While holding one front wheel from spinning, manually turn the other front wheel. In this case, the crankshaft of the engine will rotate;
- place the car on a flat horizontal platform, then turn on the 5th gear and manually move the car forward or backward;
- place the transmission in neutral and apply the handbrake. Using a wrench, turn the engine crankshaft at the crankshaft pulley bolt.
Warning: Do not turn the engine crankshaft by the camshaft pulley bolt, as in this case the load on the toothed belt is maximum.
Manual Transmission
3. Remove the plug in the clutch housing.
4. Rotate the engine crankshaft until the mark "0" on the flywheel will not align with the pointer on the clutch housing (arrow). When the marks are aligned with the pointers, the piston of the first cylinder is at TDC on the compression stroke (A - AGP engine, B - AGR, AHF, ALH engines).
Automatic transmission
5. Turn the engine crankshaft until the mark "0" will not appear on the left in the torque converter window (arrow). In this case, the piston of the first cylinder is at TDC on the compression stroke.
SDI diesel engine
6. Remove the intake manifold.
7. Remove the top casing of a gear belt and a cover of a head of the block of cylinders.
8. If the toothed belt is to be reinstalled, use a marker or paint to mark the direction of rotation of the toothed belt. When viewed from the front of the engine, the engine pulleys rotate clockwise.
9. unscrew the bolts (indicated by arrows), securing the expansion tank and the power steering reservoir and, without disconnecting the hoses from them, move them to the side.
10. Install blocking tool 3418 into the groove in the end of the camshaft.
11. With the locking tool installed in the camshaft, rotate the camshaft (turning the crankshaft clockwise) so that one side of the locking tool is pressed against the surface of the cylinder head. Using a feeler blade, measure the clearance between the second end of the locking tool and the cylinder head. Turn the camshaft slightly back and on both sides between the blocking tool and the cylinder head, install two feelers with a thickness equal to half the previously measured clearance.
12. Block the fuel pump pulley with the VW-3359 locking pin. Unscrew the bolts from the fuel pump pulley (1) and in their place, screw in new bolts, tightening them at this stage by hand. Unscrewing the bolts must be done in turn, as sections of the fuel pump pulley may move. Do not unscrew the center nut (2) fastening the fuel pump pulley, as this may move the pulley.
13. Due to the fact that the right support of the power unit prevents the removal of the toothed belt, it is necessary to support the engine with a special tool VW 10-222A and remove the right support of the power unit.
14. The engine can be supported from below with 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 engine holder.
17. unscrew the bolts (indicated by arrows), fastening the holder of the right support of the power unit to the engine.
18. Loosen the toothed belt tensioner nut.
19. Remove toothed belt from engine pulleys.
Warning: Do not bend the toothed belt sharply, as during operation the toothed belt may break at the point of a sharp bend, which will lead to engine damage.
20. After removing the toothed belt, do not change the position of the toothed belt pulleys.
Warning: If the engine crankshaft is rotated after the toothed belt has been removed, the pistons will hit the valves, causing damage to the valves and requiring extensive engine repair. Mark the position of the crankshaft pulley by marking the pulley and engine block with paint. If necessary, you can turn the engine crankshaft 90°clockwise or counterclockwise.
Warning: Check the toothed belt for wear, splitting or oiling. If there are traces of oil on the toothed belt, find the source of the oil leak and repair it before installing a new belt.
Warning: Do not twist or kink the toothed belt. Do not expose the toothed belt to oil, coolant or fuel.
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