Caution! Mark the installation position of the upper timing cover, especially at the junction with the middle part of the cover.
1. Turn the top cover latch counterclockwise (see arrow A in the illustration), so that the slot on the latch head is positioned vertically.
2. Remove the upper timing cover by pushing the locking tabs upwards (see arrow B in Illustration 8.1).
3. Apply the parking brake and place the transmission in neutral.
4. Turn the crankshaft by the central bolt securing the toothed belt gear clockwise in the direction of engine rotation until the marks on the gear align (see arrow in illustration) and on the crankshaft.
Installing a timing belt
Important! This manual does not provide a detailed procedure for removing and installing the timing belt on a 1.6-liter, 74 kW (102 hp) BGU/BSE/BSF petrol engine. Only the main points regarding belt installation are provided.
Caution: Support the engine with a garage lift or secure it to a hoist and remove the right engine mount.
Installation
Attention! If the toothed belt was removed only from the camshaft gear during repair, it is still necessary to install and adjust it.
5. Make sure that the piston of cylinder No.1 is at TDC. If necessary, turn the crankshaft or camshaft.
Caution! When turning the camshaft without a timing belt, none of the pistons should be at TDC. Otherwise, this may lead to significant damage to the valves or pistons.
6. Place the timing belt on the crankshaft gear and water pump gear.
Attention! Maintain the previous direction of rotation of the toothed belt.
7. Replace the middle and lower parts of the timing cover and secure them with bolts.
8. Install the belt pulley onto the crankshaft so that the hole on the belt pulley aligns with the thickening on the toothed belt gear on the crankshaft.
In this position of the belt pulley, screw in the new bolts for its fastening and tighten them with a force of 10 Nm, and then turn them by 90°.
9. Place the timing belt on the tension roller and camshaft gear.
Timing Belt Tension
Caution! The engine must not be hot.
10. Make sure that the markings on the camshaft pinion and the rear cover of the timing chain drive, as well as on the crankshaft belt pulley and the lower part of the safety cover of the timing chain drive match.
11. Check the mounting position of the tension roller. Locking lug (see arrow in illustration) should be in the recess on the cylinder head. Otherwise, turn the roller.
12. Turn the tension roller by the eccentric with the VW-TI0020 or HAZET 2587 cam key five times in both directions until it stops before tensioning the toothed belt.
13. Turn the eccentric with a trunnion key counterclockwise until it stops (see arrow in illustration).
14. Slowly release the toothed belt so that notch 1 and arrow 2 are positioned opposite each other. Use a mirror if necessary to check the position of the reference marks. In this position of the roller, tighten nut 3 with a force of 23 Nm (see illustration 8.13).
15. Turn the crankshaft two revolutions in the direction of engine rotation to set the piston of cylinder No.1 to TDC.
When doing this, it is important that the remaining 45° (1/8 turn), remaining until the completion of the revolution were performed in one continuous movement.
All reference marks must match when the timing belt is tensioned. Otherwise, the timing belt must be removed and reinstalled.
16. Check the tension of the toothed belt again. The arrow on the tension roller should match the notch. Otherwise, repeat the adjustment and tension of the toothed belt.
17. Check the operation of the tension roller. To do this, press the toothed belt with your thumb.
Arrow 2 on the roller should move (see illustration 8.13). Release the belt, turn the crankshaft two revolutions in the direction of engine rotation to set the piston of cylinder No.1 to TDC.
When performing this action, it is important that the remaining 45° (1/8 turn), remaining until the end of the revolution, were performed in one continuous movement. The arrow on the tension roller must match the notch. Otherwise, the toothed belt tension roller is faulty and must be replaced.
18 Secure the engine bracket to the mounting location on the cylinder block by screwing in and tightening both upper bolts to 45 Nm.
19. Lower the raised engine, insert the lower bracket mounting bolts and tighten them to 45 Nm.
20. Install the engine mount support, see the relevant chapter.
21. Secure the engine mount support to the bracket (see arrows in the illustration), screw in the bolts and tighten them to 60 Nm + 90°.
22. Remove the garage jack from under the engine or remove the hoist from the engine eyes.
23. Reinstall the upper part of the timing cover by turning the latches clockwise until the slot on the latch head is horizontal.
24. Lay the V-belt.
25. Reinstall the upper engine cover.
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