Note: A repair kit is gradually being introduced to secure the poly V-belt drive gear.
Note: The repair kit includes one support bushing and two washers of different internal diameters with a diamond coating. Both of these washers prevent the crankshaft from turning when tightening the mounting bolt.
Note: Always use a new mounting bolt before installing the repair kit. The support bushing may be reused.
Note: Using a repair kit.
Repair kit with mounting bolt
Fig. 2.22. Mounting bolt: 1 – mounting bolt; 2 – diamond coated washer (inner diameter 19 mm); 3 – support sleeve; 4 – O-ring round section; 5 – diamond coated washer (internal diameter 23 mm)
See Fig. 2.22.
Work execution procedure
Open the wiring guides and disconnect the plug from the EGR valve.
The original text can be found on the portal: vwmanual.ru
Fig. 2.23. Exhaust camshaft plug
Unscrew bolts 1 and remove plug 2 of the exhaust camshaft (Fig. 2.23).
Turn the crankshaft in the direction of engine rotation to TDC of the first cylinder.
Fig. 2.24. Place of marking
Mark the position of the hole in the exhaust camshaft 1 and on the camshaft housing 2 with a coloured pencil (Fig. 2.24).
Note: Check that the mating surfaces from the mounting bolt to the crankshaft sprocket are free of oil and grease.
First, fit the support sleeve 3 and washer 2 (internal diameter 23 mm) on the mounting bolt 1.
Screw the mounting bolt 1 into the crankshaft approximately 2 turns.
Fig. 2.25. Installing the support sleeve
Then place washer 2 and support sleeve 3 on the crankshaft journal until they stop (Fig. 2.25).
Unscrew the mounting bolt (while doing this, press the support sleeve against the crankshaft).
Install a new crankshaft oil seal on the belt pulley side.
Fig. 2.26. Fastening bolt and gear of the poly V-belt drive
Screw in a new mounting bolt 1 with the poly V-belt drive gear 2 and washer 3 (inner diameter 19 mm) into the crankshaft journal (Fig. 2.26).
Always use a new bolt.
A new mounting bolt can be identified by its pre-drilled head.
Note: When tightening, do not allow the poly V-belt drive gear to accidentally rotate at an angle (180°) with the locking key.
Tightening torque 150 Nm + additional 1/2 turn (180°).
Hold the poly V-belt drive gear with a locking wrench.
Check the position of the exhaust camshaft.
Both marks 1 and 2 must match.
If both marks 1 and 2 do not match, repeat the operations with a new washer (Fig. 2.24).
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