Contents: Removal ↓ Installation ↓
4-cylinder petrol engine
Removal
Before 9/93: Remove V-belt, see below in this chapter.
From 10/93: Remove the V-belt and, if fitted, the tensioner roller, see later in this chapter.
Set the crankshaft to the TDC position for cylinder 1 and do not change the adjustment any further, see chapter "Ignition system".
Unscrew both V-belt pulleys or, respectively, the torsional vibration damper from the crankshaft.
Remove the upper and lower timing belt covers.
Use a felt-tip pen or marker to mark the direction of movement of the timing belt with an arrow when the engine is running.
Loosen and remove the toothed belt.
Caution: If possible, do not change the engine adjustment when the timing belt is removed.
Installation
Place the toothed belt on the toothed wheels of the crankshaft and intermediate shaft.
Caution: The arrow on the belt must point in the direction of rotation of the engine shaft.
Secure the crankshaft pulley with one bolt. Secure the injection engine vibration damper with all four bolts.
Check whether the camshaft is at TDC for cylinder 1. At the same time, the marks on the crankshaft and intermediate shaft pulleys (arrow) in the right figure should match. In this case, the crankshaft is at TDC for cylinder 1.
Note: For an engine with the AEK designation, the position of the mark on the intermediate shaft gear is of no importance. The correspondence of the crankshaft to the TDC position for cylinder 1 is checked through the inspection hole in the gearbox housing. Namely: through the round hole it should be visible that the "O" mark on the flywheel is located opposite the mark on the housing. Check whether the runner in the ignition distributor housing points to the TDC mark for cylinder 1 (figure 28-345), if necessary, turn the intermediate shaft wheel in the direction of rotation of the engine crankshaft, see chapter "Ignition system".
Caution: For engines with a rear timing belt guard, the TDC mark on the camshaft gear must coincide with the TDC mark on the guard.
If necessary, turn the camshaft until the mark on its toothed wheel coincides with the mark on the cylinder head cover or toothed belt protective screen.
Caution: If the camshaft needs to be turned at a large angle, make sure that none of the pistons are in the TDC position, otherwise the valves or pistons may be damaged. If necessary, turn the crankshaft by approximately 90° (1/4 turn) in a clockwise or counterclockwise direction. However, the belt pulley as a whole should not turn more than 90°.
Place the timing belt on the camshaft gear.
Caution: When applying the timing belt, do not change the position of the camshaft, crankshaft or intermediate shaft. Otherwise, serious damage to the engine may occur or it will no longer deliver its full power. After the timing belt has been tensioned, check the adjustment of the camshaft, intermediate shaft and belt pulley again. This means: If the mark on the camshaft gear coincides with the mark on the protective screen, then at the same time the mark on the crankshaft belt pulley must coincide with the mark on the intermediate shaft gear. Otherwise, it is necessary to repeat the adjustment of the camshaft gear and belt pulley with the timing belt removed.
Tighten the timing belt.
Turn the crankshaft in the direction of engine rotation by two revolutions and check the adjustment again.
Remove the crankshaft belt pulley.
Install the lower timing belt cover.
Install the upper belt cover.
Install the crankshaft belt pulley and tighten to a torque of 20 Nm (for engines with the AEK designation - 25 Nm).
Install and tension the V-belt, see below in this chapter.
Install the poly V-belt and tension roller (20 Nm), tighten the poly V-belt, see below in this chapter.
Check the ignition timing and adjust if necessary.
Caution: For repairs that require removing the timing belt from the camshaft gear only, adjust the timing belt as follows:
Set the crankshaft to TDC for cylinder 1, see chapter "Ignition system".
The mark on the camshaft gear must match the mark on the cylinder head cover, see Figure 13-689.
Loosen the toothed belt and remove it from the camshaft gear.
Note: After this, the position of the crankshaft and intermediate shaft should not be changed any more.
Place the toothed belt on and tighten it.
Remove the distributor cap. Check whether the rotor in the distributor housing points to the TDC mark for cylinder 1.
If this is not the case, turn the ignition distributor so that the marks match. If necessary, reinstall the ignition distributor, see chapter "Ignition system".
Turn the crankshaft twice and check whether the marks on the camshaft and crankshaft match the corresponding marks on the casings.
Check the ignition timing, adjust if necessary, see chapter "Ignition system".
(The original article is posted on the website: VWMANUAL.ru)
Start the engine. A whistling sound from the timing belt indicates that the belt is too tight.
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