Timing Belt — removal and installation (VW Lt 28)

1. Remove the engine cover (see previous section).

2. Remove the bolts securing the expansion tank of the cooling system and move it to the side.

3. Loosen the generator mounting bolts and its adjusting rod, turn the generator towards the engine and remove the drive belt from the pulleys (see photo).

Photo 5.3. Removing the generator drive belt.

4. Loosen the screws and remove the timing belt cover (see photos).

Photo 5.4A. Removing the upper right timing belt cover bolt.

Photo 5.4B. Removing the upper left timing belt cover bolt.

Photos 5.4C. Removing the front timing belt cover bolt.

Photo 5.4D. Removing the timing belt cover.

5. Loosen the bolts and remove the fan impeller from the flange on the front surface of the crankshaft pulley.

6. Rotate the crankshaft using a wrench placed on the crankshaft pulley bolt, or by leaving two bolts in the holes on the front flange of the pulley and turning the pulley with a long lever until the mark on the rear surface of the camshaft sprocket aligns with the pointer on the camshaft cover, and the TDC mark on the flywheel aligns with the protrusion on the clutch housing (the center of the "0" aligns with the pointer). If this operation is performed on an engine removed from the vehicle, alternative TDC marks should be used (notch on the crankshaft pulley and an indicator on the oil pump).

Figure 1.2. Camshaft timing marks (section 5).

Figure 1.3. TDC timing marks on the flywheel/clutch housing and on the crankshaft pulley/oil pump (section 1.5).

7. Loosen the lock bolt screwed into the offset hole on the head of the large hex eccentric located in the center of the timing belt tensioner.

8. Turn the eccentric to relieve tension from the belt.

9. Remove the belt with the camshaft sprockets, then pull it out of the groove on the tensioner pulley and remove it from the crankshaft sprocket. If you are not going to change the belt, mark the direction of its movement on it (see photo).

Photo 5.9. Removing the timing belt.

10. Do not turn the crankshaft or camshaft with the timing belt removed, as this may cause the valves to hit the pistons and damage them.

11. The belt is installed in reverse order. First check that the camshaft sprocket and flywheel marks have not shifted from their specified positions (see photo).

Photo 5.9. Removing the timing belt.

12. After installing the belt, tighten it by turning the eccentric on the tensioner pulley counterclockwise so that by grasping the belt between your thumb and index finger at the middle point of its longest run, you can twist it no more than 90° (see photos).