Contents: Removal ↓ Installation ↓
Removal
Caution: Risk of fuel leakage! The fuel in the fuel system is under pressure. Before disconnecting the system elements, the connection point must be wrapped with a rag. Then, by carefully loosening the connection, you need to release the pressure.
Please note: the timing belt adjustment should only be performed on a cold engine, as the tensioner adjustment position changes depending on the temperature.
1. Remove the engine cover. To do this, sharply pull the front engine cover (arrow A) up from the rear mount and then forward (arrow B).
2. Disconnect the fuel injection hose (2), fuel return hose (1), and coolant hose (3).
3. Remove the connecting pipe between the charge air cooler and the exhaust pipe by slightly lifting the clamps (arrows).
4. After pulling out the clamps, disconnect the pressure (3) and return (2) fuel lines.
5. Remove the fuel filter (arrow) from the bracket.
6. Unscrew the bolt on the neck (1) of the washer reservoir.
7. Unscrew the fuel filter bracket (3).
8. Disconnect the electrical connector on the coolant expansion tank (1),
9. Unscrew the expansion tank (do not disconnect the hoses that go with it) and take him aside.
10. Remove the poly V-belt.
11. Remove the poly V-belt tensioner.
12. Remove the upper timing belt cover.
13. Remove the front right wheel arch liner.
The information is available on the website: www.VWmanual.ru
14. Remove the crankshaft pulley.
15. Remove the lower and middle timing belt covers.
16. Bring the crankshaft to the TDC position of the first cylinder.
17. Turn the crankshaft until the mark on its toothed pulley and the toothed segment of the camshaft pulley are in the upper position. In this case, the mark on the camshaft pulley should coincide with the mark on the timing belt cover behind the pulley (arrow).
18. Secure the hub with the locking device. To do this, insert the retainer into the hole in the cylinder head through the free concentric groove on the left side of the camshaft toothed pulley.
19. Fix the crankshaft toothed pulley. The marks on the crankshaft timing pulley and on the crankshaft locking pin must match. In this case, the retainer pin should enter the hole in the front cover of the cylinder block.
20. Mark the direction of movement of the toothed belt.
21. Loosen the mounting screws (1) of the camshaft pulley so that it can rotate in the concentric grooves.
22. Loosen the nut (1) securing the tension roller.
23. Rotate the tension roller eccentric counterclockwise (arrow) using a socket wrench until the tension roller can be secured with the locking pin.
24. Turn the tension roller eccentric clockwise (arrow) until it stops and tighten the fastening nut (1) by hand.
25. Remove the toothed belt first from the coolant pump pulley, and then from the other toothed pulleys.
Installation
1. Fix the camshaft using the locking device (1).
2. Fix the crankshaft using the crankshaft locking tool.
3. Fix the tension roller with a clamp and secure it with a nut in the extreme right position.
4. Turn the camshaft pulley so that it occupies the middle position in the concentric grooves (arrows).
5. Pass the timing belt between the engine mount and the engine.
6. Install the timing belt on the crankshaft pulley, tension roller, camshaft pulley and idler roller.
7. Lastly, the belt is installed on the coolant pump pulley.
8. Ensure the proper position of the tension roller in the rear timing belt housing (arrow).
9. Remove the retainer from the tension roller.
10. Loosen the tension roller fastening nut (1).
11. Turn the tension roller eccentric clockwise (arrow) using a socket wrench until the pointer (2) is in the middle of the hole in the base. The fastening nut should not rotate.
12. While holding the tension roller in this position, tighten the fastening nut as follows: 20 Nm and turn further by 1/8 of a turn (45°).
13. Install the camshaft timing pulley retainer with pins as shown in the figure.
14. Apply force to the retainer in the direction indicated by the arrow to hold the toothed pulley.
15. Tighten the camshaft pulley mounting screws (1) in this position to a torque of 25 Nm.
16. Remove the camshaft hub locking pin and crankshaft locking pin (T10050 or T10100).
17. Secure the camshaft hub with a locking device.
18. Check whether the crankshaft can be fixed in this position using a locking device (T10050 or 710100). If the crankshaft cannot be fixed, then the following steps must be performed..
- Loosen the camshaft pulley mounting screws (1).
- Turn the crankshaft slightly in the opposite direction until the locking pin is almost at the corresponding hole in the crankshaft cover (arrow).
- Rotate the crankshaft in the working direction so that the locking pin enters the hole during rotation.
19. Install the camshaft timing pulley retainer (2) with pins (3) as shown in the figure.
20. Apply force to the retainer in the direction indicated by the arrow to hold the toothed pulley.
21. Tighten the camshaft pulley mounting screws (1) in this position to a torque of 25 Nm.
22. Remove the camshaft hub locking pin (4) and the crankshaft locking pin (T10050 or T10100).
23. Turn the crankshaft two revolutions in the direction of engine rotation so that the piston of the 1st cylinder takes a position close to TDC.
24. Repeat the check and adjust if necessary.
25. Install the middle and lower timing belt covers.
26. Install the vibration damper/pulley. Tightening torque: 10 Nm + 90° (1/4 turn).
27. Install the poly V-belt.
28. Install the upper timing belt guard.
29. Install the right front fender liner.
30. Install the expansion tank of the cooling system.
31. Screw the fuel filter bracket to the engine mount with a torque of 8 Nm (arrows).
32. Fix the fuel filter in the bracket.
33. Screw on the washer reservoir neck.
34. Install the engine cover.
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