Release of the toothed belt tensioner on the 1.8-I engine
- The arrow points to the fixing pin with a diameter of 1.5 mm;
- 1 - set screw, M5x55;
- 2 - hex nut;
- 3 - washer
Order of execution
1. Remove the top casing of a gear belt.
2. If the toothed belt is to be reinstalled, use a marker or paint to mark the direction of rotation of the toothed belt.
3. When viewed from the front of the engine, the engine pulleys rotate clockwise.
4. Turn the crankshaft of the engine so that the piston of the first cylinder is at top dead center.
5. 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.
6. Turn the engine crankshaft until the mark on the camshaft pulley (picture above) not aligned with the TDC indicator on the cylinder head cover Check that the mark on the crankshaft pulley (picture below) aligned with the pointer on the lower timing belt cover. The marks are indicated by arrows. When the marks are aligned with the pointers, the piston of the first cylinder is at TDC on the compression stroke.
7. 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.
8. The engine can be supported from below with a jack through a wooden block.
9. While holding the crankshaft pulley from turning, unscrew the four bolts securing the pulley to the crankshaft.
10. Remove the crankshaft pulley.
11. Unscrew and remove the lower and middle casings of the toothed belt.
12. unscrew the bolts (indicated by arrows), that secure the expansion tank and the power steering reservoir, and without disconnecting the hoses from them, move them to the side.
13. unscrew the bolts (indicated by arrows), fastening the right support of the power unit to the body and engine holder.
14. unscrew the bolts (indicated by arrows), fastening the holder of the right support of the power unit to the engine.
Engine 1.6-I
15. Loosen the toothed belt tensioner bolt (see fig. Using a wrench to rotate the timing belt tensioner on the eccentric on the 1.6-I engine).
Engine 1.8-I
16. Screw the M5x55 set screw into the toothed belt tensioner. Screw hex nut 2 with large washer 3 onto set screw 1 (see fig. Release of the toothed belt tensioner on the 1.8-I engine).
17. After aligning the holes in the piston and body, insert a steel rod or drill shank with a diameter of 1.5 mm into the aligned holes. This fixes the tension roller in the retracted position, as a result of which the tension of the toothed belt will loosen.
18. 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.
Warning: 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.
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