Contents: Removal ↓ Installation ↓
Removal
1. Place the machine on supports.
2. Remove the lower engine compartment cover.
3. Remove the car from the supports.
4. Remove the V-belt.
5. Set the crankshaft to the TDC position for the first cylinder. Rotate the crankshaft clockwise.
6. The crankshaft is at TDC if the mark on the camshaft gear coincides with the mark on the rear timing belt cover.
7. At the same time, the mark on the flywheel or clutch driven disk must match the TDC mark. The figure shows both corresponding marks on the vibration damper and on the toothed belt cover. These marks are used to adjust the TDC on a removed engine.
8. Remove the upper timing belt cover. Using a felt-tip pen or grease pencil, mark an arrow on the belt in the direction of its rotation. The engine rotates, when viewed from the front, clockwise to the right.
9. Loosen the timing belt (see subsection 2.5.1.3).
10. Unscrew the vibration damper from the crankshaft timing belt gear by unscrewing 4 M8 bolts.
11. Remove the timing belt.
Attention! The toothed belt must not have any cuts. A toothed belt with cuts must be replaced, as it may break during operation, which will lead to serious damage to the engine.
12. If possible, do not change the position of the timing belt gears.
Installation
Attention! If you are installing an old toothed belt, be sure to pay attention to the direction of movement. Installing the toothed belt in the opposite direction can lead to its breakage and engine failure!
1. Place the timing belt on the crankshaft gear, idler pulley and water pump.
2. Screw the vibration damper with 4 bolts to a torque of 20 Nm.
3. Screw on the lower timing belt cover. Otherwise, rotate the camshaft so that the mark on the camshaft drive gear aligns with the top edge of the cylinder head cover gasket.
Caution! If the camshaft is rotated with the timing belt removed, no piston should be at TDC. Otherwise, severe damage to the pistons or valves may occur.
Attention! If it is necessary to turn the camshaft, first set all pistons to the same height. To do this, apply a chalk mark on top of the crankshaft belt pulley (prerequisite: the crankshaft is in the TDC position for cylinder 1), then turn the crankshaft belt pulley 1/4 turn (90°) to the left or right, using the chalk mark as a guide.
4. Check the crankshaft position at TDC for cylinder 1. The TDC mark (0) on the flywheel should be visible in the inspection hole of the clutch housing, located exactly next to the installation edge.
5. If the timing belt is to be installed on a removed engine, the notch on the belt pulley must match the installation mark on the cylinder head cover. In this case, the crankshaft is in the TDC position for cylinder 1.
6. Put on the timing belt.
Attention! When installing the timing belt, do not change the position of the camshaft and crankshaft. Otherwise, the engine may be seriously damaged or will not develop full power. After tensioning the timing belt, check the position of the camshaft and crankshaft again. This means: if the mark on the camshaft gear coincides with the upper edge of the cylinder head cover gasket, then at the same time the TDC marking on the flywheel must coincide with the corresponding mark. Otherwise, repeat the adjustment of the camshaft drive gear and crankshaft gear.
7. Tighten the timing belt.
8. Turn the crankshaft 2 revolutions in the direction of its rotation and check the adjustment and tension again.
9. Install the upper timing belt cover.
10. Screw on the V-belt tensioner.
(The original can be found at: «VWManual.ru»)
11. Install and tension the V-belt.
12. Install the engine splash guard.
13. For repairs that require removing the timing belt only from the camshaft gear, adjust the timing belt as follows:
- set the crankshaft to TDC for cylinder 1;
- loosen and remove the timing belt from the camshaft gear;
- put on and tighten the timing belt;
- the position of the camshaft and crankshaft should not be changed during repairs.
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