Important! This manual does not provide a detailed description of replacing the timing belt on 1.9-liter diesel engines. Below are only the basic steps for installing the timing belt.
1. Set the piston of cylinder No.1 to TDC.
2. Mark the direction of rotation of the toothed belt.
3. Loosen bolts 1 securing the camshaft drive gear so that the gear can move freely in the longitudinal holes for the bolts (see illustration).
4. Loosen the timing belt tension roller mounting nut.
5. Turn the tension roller counterclockwise with the HAZET-2587-I trunnion key (see arrow in illustration) so that it can be locked in place using a suitable roller, such as VW-T10115.
6. Turn the trunnion key clockwise until it stops without removing the locking roller, and tighten the roller nut by hand.
Caution! For vehicles with a 2.0-liter engine, the timing belt tension roller must be turned using a hex key. A cam key may only be used if a socket key is not available.
7. Remove the timing belt. The timing belt is removed from the water pump drive gear first.
Installation
8. Install the gear on the camshaft so that the bolts in its longitudinal holes are centered.
9. Place the toothed belt on the crankshaft gear, tension roller, camshaft gear, guide roller. Lastly, place the belt on the water pump drive gear.
10. Make sure that the protrusion on the tension roller enters the rear timing cover housing.
11. Loosen the timing belt tension roller mounting nut and remove the stop pin.
12. Turn the tension roller clockwise with a trunnion key until the roller arrow is centered in the hole on the support plate (see arrow in illustration). Make sure that the roller mounting nut does not turn either.
13. Hold the tension roller in this position and tighten its mounting nut with a force of 20 Nm, and then turn it by 45° (1/8 turn).
14. Turn the timing belt gear on the camshaft with a cam key B, for example HAZET 2540-1 or VW-T10172, in the direction of the arrow as shown in the illustration and hold it in this position.
15. Tighten the gear mounting bolts in this position with a force of 25 Nm.
16. Remove the thrust roller and remove the locking device from the gear on the crankshaft.
17. Turn the crankshaft two revolutions in the direction of engine rotation (clockwise) and set the piston of cylinder No.1 to TDC again. Before completing the second revolution, insert the thrust roller HAZET 2588-3 (see illustration 14.14).
18. Make sure that the crankshaft can be locked using the locking device, which is installed on the timing belt sprocket on the crankshaft.
If the locking device protrusion does not enter the sealing flange, then the following must be done:
19. Remove the locking device and turn the crankshaft so that the hub of the timing belt gear on the camshaft can be fixed with the thrust roller.
20. Loosen the timing belt gear mounting bolts on the camshaft.
21. Turn the crankshaft slightly against the direction of engine rotation so that the projection of the locking device 2588-1 is only slightly out of alignment with the hole in the sealing flange (see arrow in illustration).
22. Now turn the crankshaft in the direction of engine rotation so that the protrusion of the locking device enters the hole in the sealing flange in the direction of rotation.
23. Turn the timing belt gear on the camshaft with cam key B, for example HAZET 2540-1, in the direction of the arrow, as shown in Illustration 14.14, and, holding it in this position, tighten the gear mounting bolts with a force of 25 Nm.
24. Remove the thrust roller and remove the locking device from the gear on the crankshaft.
25. Turn the crankshaft two revolutions in the direction of engine rotation (clockwise) and set the piston of cylinder No.1 to TDC again.
26. Secure the engine mount bracket to the cylinder block by tightening the mounting bolts to 45 Nm.
27. Secure the engine mount support to the body with new bolts.
The tightening torque for M8 bolts is 20 Nm + 90° turn (1/4 turn), tightening torque for M10 bolts - 40 Nm + 90° turn (1/4 turn).
28. Connect the support and engine mount bracket with bolts, tightening them with a force of 60 Nm/90° turn (1/4 turn).
29. Reinstall the middle and lower parts of the timing cover.
30. Install the accessory drive belt pulley onto the crankshaft and secure it with a bolt.
Pulley bolt tightening torque 10 Nm + 90° turn (1/4 turn).
31. Install the V-belt, see the relevant chapter.
32. Reinstall the upper part of the timing cover.
33. Reinstall the charge air/turbocharger cooler and charge air cooler, intake manifold connecting hoses.
34. Install the mudguard liner into the right wheel arch.
35. Install the lower engine guard and upper engine guard cover.
36. Install the coolant expansion tank in place.
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