Toothed belts, removing, installing and tensioning: Installing

WARNING: This page is about a different car, the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Adjustment work on toothed belts must only be performed on cold engines as the indicator on the tensioning element alters depending on the engine temperature.
The tensioning roller must be locked with locking pin T10115 and secured to the right limit stop.

Fig 1: Turning Camshaft Pulley

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn camshaft pulley in elongated holes counter-clockwise - in direction of arrow - onto limit stop.
Install toothed belt to crankshaft pulley, belt tensioner and camshaft pulley.
Install toothed belt onto coolant pump toothed belt pulley.

Fig 2: Identifying Tensioning Roller

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Ensure that tensioning roller seats correctly in rear toothed belt guard - arrow -.

Loosen tensioning roller securing nut.
Relieve tension on tensioning roller by turning pin wrench in opposite direction of - arrow - and remove locking pin from tensioning roller.

Fig 3: Identifying Pin Wrench 3387

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully turn tensioning roller with pin wrench 3387 in direction of arrow until indicator is in middle of gap in base plate - arrow -.
Hold tensioning roller in this position and tighten tensioning roller securing nut as follows: 20 Nm and 45 ° ( 18 turn) further.
Tighten camshaft pulley securing bolts to 25 Nm.
Remove locking pin 3359 and crankshaft stop T10050.

Turn crankshaft two rotations in direction of engine rotation and set again to TDC No. 1 cylinder.

NOTE:

As this is done, the shaft of the crankshaft stop must be able to engage in the sealing flange from direction of engine rotation.
If the crankshaft is turned past TDC No. 1 Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 14 turn to be able to turn the crankshaft in the direction of engine rotation again to set it to TDC No. 1 cyl. It is not permitted to turn the engine opposite to the normal direction of rotation when turning to ensure the crankshaft stop will engage.

Once crankshaft stop T10050 has engaged, check whether hub can be fixed in place using locking pin 3359.

If the hub cannot be locked:

Pull crankshaft stop pin out of hole in sealing flange and turn crankshaft until hub can be locked with locking pin.

Fig 4: Identifying Camshaft Pulley Securing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen camshaft pulley securing bolts - 1 -.

Fig 5: Identifying Crankshaft Stop T10050

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Turn crankshaft slightly against direction of engine rotation until crankshaft stop pin is positioned just before hole in sealing flange - arrow -.
Turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange while turning.
Tighten camshaft pulley securing bolts to 25 Nm.
Remove locking pin 3359 and crankshaft stop T10050.

Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.

NOTE:

As this is done, the shaft of the crankshaft stop must be able to engage in the sealing flange from direction of engine rotation.
If the crankshaft is turned past TDC No. 1 Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 14 turn to be able to turn the crankshaft in direction of engine rotation again to set it to TDC No. 1 cyl. It is not permitted to turn the engine opposite to the normal direction of rotation when turning to ensure the crankshaft stop will engage.

Repeat check.
Install lower toothed belt guard and vibration damper/belt pulley.
Install center toothed belt guard.

Fig 6: Identifying Engine Mounting Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install engine mounting to cylinder block and tighten - arrows -. Tightening torque: 45 Nm
Install top toothed belt guard.

NOTE:

Before installing the assembly mounting, all engine mounting bolts must be tightened to prescribed torque.

Install engine/body assembly mounting (replace securing bolts). Tightening torque: 40 Nm plus an additional 90 ° ( 14 turn).
Align engine and transmission mountings. Refer to Engine and transmission mountings, aligning .
Tighten engine assembly mounting to engine bracket. Use support device 10-222 A to bring contact surfaces into position. Tightening torque: 100 Nm
Install bracket for body assembly mounting. Tightening torque: 25 Nm
Install coolant expansion tank.
Install power steering reservoir and fuel filter.
Install charge air pipe between charge air cooler and intake connecting flange. Refer to Charge air cooling components, removing and installing .
Install poly V-belt tensioning element. Tightening torque: 25 Nm
Install poly V-belt. Refer to Poly V-belt, removing and installing .
Install right side insulation tray: Refer to 94 LIGHTS, SWITCHES - EXTERIOR
Install sound insulation tray.