Attention! Mark the mounting position of the top cover of the timing gear, 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 vertical.
2. Remove the top cover of the timing gear drive by pressing up the locking tabs (see arrow B in illustration 8.1).
3. Apply the parking brake and place the transmission in neutral.
4. Turn the crankshaft at the central bolt of the toothed belt gear clockwise in the direction of engine rotation until the marks on the gear coincide (see arrow in illustration) and on the crankshaft.
Timing belt installation
Attention! This manual does not provide a detailed procedure for removing and installing the timing belt for a 1.6 liter 74 kW gasoline engine (102 hp.) BGU/BSE/BSF. Only the main points regarding the installation of the belt are given.
Attention! Support the engine with a garage lift or hoist and remove the right engine mount.
Installation
Attention! If the toothed belt was removed only from the camshaft gear during the repair, then it is still necessary to lay and adjust it.
5. Make sure the #1 cylinder piston is at TDC. If necessary turn a cranked shaft or distributive.
Attention! When turning the camshaft without a toothed belt, none of the pistons should be at TDC. Failure to do so may result in significant damage to valves or pistons.
6. Lay the toothed belt over the crankshaft gear and water pump gear.
Attention! Observe the same direction of rotation of the toothed belt.
7. Reinstall the middle and bottom parts of the timing cover and secure them with bolts.
8. Install the belt pulley on the crankshaft so that the hole on the belt pulley matches the boss on the toothed belt gear on the crankshaft.
In this position of the belt pulley, screw in the new bolts of its fastening and tighten them with a force of 10 Nm, and then tighten by 90°.
9. Lay the toothed belt over the tension roller and camshaft gear.
Toothed belt tension
Attention! The engine must not be hot.
10. Make sure that the marks on the camshaft gear and the back cover of the timing gear, as well as on the crankshaft belt pulley and the bottom of the protective cover of the timing drive, match.
11. Check the mounting position of the tension roller. Locking lug (see arrow in illustration) must be located in the recess in the cylinder head. Otherwise, check the roller.
12. Turn the tension roller by the eccentric with the VW-TI0020 or HAZET 2587 trunnion key five times in both directions until it stops before tensioning the toothed belt.
13. Turn the eccentric with a pin wrench counterclockwise until it stops (see arrow in illustration).
14. Slowly release the toothed belt so that notch 1 and arrow 2 are set opposite each other. If necessary, use a mirror to check the position of the reference marks. In this position of the roller, tighten the fastening nut 3 with a force of 23 Nm (see illustration 8.13).
15. Rotate the crankshaft two turns in the direction of engine rotation to set the No. 1 cylinder piston to TDC.
When performing this action 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 toothed belt is tensioned. Otherwise, the toothed belt should be removed and reinstalled.
16. Check again the toothed belt tension. The arrow on the tension roller must align with the notch. Otherwise, repeat the adjustment and tension of the toothed belt.
17. Check up functioning of a tension roller. To do this, wring out the toothed belt by pressing on it with your thumb.
Arrow 2 on the roller should move (see illustration 8.13). Loosen the belt, turn the crankshaft two turns in the direction of engine rotation to set the No. 1 cylinder piston to TDC.
When performing this action, it is important that the remaining 45° (1/8 turn), remaining until the completion of the revolution, were performed in one continuous movement. The arrow on the tension roller must align with the notch. Otherwise, the toothed belt tensioner is defective and must be replaced.
18 Fasten 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, see relevant chapter.
21. Attach the engine mount to the bracket (see arrows in illustration), screw in the bolts and tighten them to 60 Nm + 90°turn.
22. Remove the garage jack from under the engine or remove the hoist from the engine lugs.
23. Replace the upper part of the protective cover of the timing gear by turning the latches clockwise so that the slot on the head of the latch is horizontal.
24. Lay the ribbed belt.
25. Replace the top engine cover.
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