Toothed Belt: Removing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

-- Remove the upper toothed belt guard, refer to TOOTHED BELT GUARD .

-- Remove the engine support, refer to ENGINE SUPPORT .

-- Remove the lower toothed belt guard, refer to LOWER TOOTHED BELT GUARD .

CAUTION: Components could be destroyed by the toothed belt jump off.

Only rotate the crankshaft in the direction of engine rotation.

-- Turn the crankshaft at the crankshaft toothed belt gear bolt until the camshaft toothed belt gear is at "Top Dead Center (TDC)".

-- Secure the camshaft hub with the Diesel Injection Pump Locking Pin 3359 by inserting the pin in the fork on the drive plate -2- and in the hole behind it -1- in the cylinder head.

Fig 1: Identifying Diesel Injection Pump Locking Pin

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-- Loosen the crankshaft holder -1- in the camshaft sprocket a half a turn, but do not remove.

Fig 2: Identifying Crankshaft Holder

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-- Secure the crankshaft toothed belt sprocket with the Crankshaft Lock T10490.

Fig 3: Identifying Crankshaft Lock T10490

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The pins on the Crankshaft Lock T10490 must engage in the threaded holes on the toothed belt sprocket.
The pin on the Crankshaft Lock T10490 must engage in the hole on the sealing flange.

CAUTION: The tightening specification for the loosening and tightening of the camshaft central bolts and high pressure pump and should not be transferred to the locking pin. If a counterholder is used the >>carriers<< may be damaged. Under some conditions, these are not visible and engine damage may be the result. For loosening and tightening the central bolts, remove the locking pin and then when necessary remove.

-- Pull the locking pin and loosen the camshaft bolt. Before completely loosening, replace the locking pin.

-- Loosen the bolt -arrow- for the camshaft toothed belt sprocket.

Fig 4: Identifying Camshaft Toothed Belt Sprocket Bolt

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-- Use the Counterhold - Kit - Multiple Use T10172 with the Camshaft Lock T10172/11.

-- Pull the locking pin and loosen the camshaft bolt. Before completely loosening, replace the locking pin.

-- Secure the hub on the high pressure pump with the Locking Pin T10492.

Fig 5: Identifying Locking Pin

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-- To do this place the locking pin in the hub prong -2- and the rear hole -1- in the auxiliary components bracket.

-- Pull the locking pin and loosen the high pressure pump toothed belt sprocket nut. Before completely loosening, replace the locking pin.

-- Loosen the nut -arrow- for the high pressure pump toothed belt sprocket approximately 90°.

Fig 6: Identifying Counterhold - Camshaft Gear And Locking Pin

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-- Use the Counterhold - Camshaft Gear T10051 to do so.

-- Loosen the nut -1- for the tensioning roller.

Fig 7: Identifying Nut

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-- Turn the tensioning roller eccentric pulley counter-clockwise using the Wrench - Tensioning Roller T10264 -arrow- until the roller can be secured with the Tensioning Roller Locking Tool T10265.

-- Then turn the tensioning roller eccentric pulley clockwise all the way using the Wrench - Tensioning Roller T10264 -arrow- and tighten the nut -1- hand-tight.

Fig 8: Identifying Wrench - Tensioning Roller T10264 And Tensioning Roller Locking Tool T10265

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CAUTION: A used toothed belt could be destroyed if the running direction is reversed.

Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for installation later.

-- Remove the toothed belt from the coolant pump and then from the remaining toothed belt gears.