- Автомобиль
- VW Crafter 2017 ->, MAN TGE 2017 ->
- Двигатель
- 2,0 TDI DASA, DASB, DAWA, DAWB, DASC
2.0L 4-cylinder common rail, 4V, turbocharger, inline engine DASA, DASB, DAWA, DAWB, DASC
Assembly overview - toothed belt cover, toothed belt
Removing and installing toothed belt guard
Removing and installing toothed belt
Adjusting valve timing
Checking valve timing
Adjustment fault through inaccurate TDC setting
Removing toothed belt from camshaft
Assembly overview - toothed belt cover
1 - Toothed belt guard, Bottom
2 - Bolts. Qty. 4, 12 Nm
3 - Bolt, 12 Nm
4 - Toothed belt guard, On side
5 - Toothed belt guard, Top
6 - Bolt, 12 Nm
7 - Toothed belt guard, Rear
Assembly overview - toothed belt
1 - Bolt, Renew after removal, Do not additionally oil the thread and shoulder, 180 Nm +135°
2 - Crankshaft, Contact surface between toothed belt pulley and crankshaft must be free from oil, Can only be fitted in one position
3 - Nut, 20 Nm
4 - Idler roller
5 - Nut, Renew after removal, 20 Nm +45°
6 - Tensioning pulley
7 - Toothed belt, Before removing, mark direction of rotation with chalk or felt-tipped marker pen.
8 - Bolt, Do not additionally oil the thread and shoulder, 100 Nm
9 - Bolt, 9 Nm
10 - Crankshaft, Contact surface between sprocket and camshaft must be free of oil
11 - Follower, For camshaft.
12 - Stud, For tensioning roller, 16 Nm
13 - Bolt, 20 Nm
14 - Idler roller
15 - High-pressure pump
16 - Hub, Contact surface between hub and toothed belt sprocket must be free of oil
17 - Crankshaft, Contact surface between hub and toothed belt sprocket must be free of oil
18 - Nut, Do not additionally oil the thread and shoulder
19 - O-ring, Renew after removal, Moisten with coolant
20 - Coolant pump
21 - Bolt
22 - Stud, For idler roller, 16 Nm
Removing and installing upper toothed belt guard
Removing
– Release retaining tabs -2- and remove upper toothed belt guard -1-.
Installing
Install in reverse order of removal.
Removing and installing side toothed belt guard
Special tools and workshop equipment required
Torque wrench - V.A.G 1331-
– Remove upper part of toothed belt guard
– Unscrew bolt -1-.
– Remove side toothed belt guard -2-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
Assembly overview - toothed belt cover
Removing and installing lower toothed belt guard
Special tools and workshop equipment required
Torque wrench - V.A.G 1331-
Removing
Note: To simplify the manufacturing process in the production facilities the lower toothed belt guard is provided with a guide at bottom which engages in the sealing flange.
When removing the toothed belt guard with engine support installed, the guide in the toothed belt guard must be destroyed.
Bear in mind that there are different versions!
– Remove viscous fan holder
– Remove vibration damper
– If a toothed belt guard version which is about to be discontinued is fitted, drill a hole according to the following dimensions:
Dimension -a- = 10 mm
Diameter: 8 mm
– Insert a screwdriver through drilled hole and break off guide lug of toothed belt guard towards rear.
– If a more recent toothed belt guard version is fitted, insert screwdriver into slot in guide lug.
– Turn screwdriver in direction of -arrow- and break off guide lug.
– Remove bolts -1-.
• Locking lug -3- broken off.
– Remove lower toothed belt guard -2-.
Installing
Install in reverse order of removal, observing the following:
– If a new toothed belt guard is installed, the guide lug -arrowmust be cut off prior to installing.
– Fit toothed belt guard -1-. Make sure that dowel pin engages on hole in coolant pump -arrow-.
Specified torques
Assembly overview - toothed belt cover
Removing and installing rear toothed belt cover
Special tools and workshop equipment required
Torque wrench - V.A.G 1331-
Removing
– Remove coolant valve for cylinder head - N489-
– Unscrew bolt -1-.
– Pull out rear toothed belt cover -2- in direction of -arrow-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
Assembly overview - toothed belt cover
Removing and installing toothed belt
Torque wrench - V.A.G 1332-
Torque wrench - V.A.G 1331-
Counterhold tool - T10051-
Counterhold tool - T10172-
Pin - T10492-
Crankshaft stop - T10490-
Angled screwdriver - T10264-
Locking tool - T10265-
Angled screwdriver AF 8 - T10409-
Removing
– Remove upper part of toothed belt guard
– Remove viscous fan pulley holder
– Remove lower toothed belt guard
• Only turn crankshaft in engine direction of rotation.
– Turn crankshaft by bolt for crankshaft pulley until camshaft pulley is at TDC.
– Lock camshaft hub with locking pin - T10492- -3-. To do this, insert locking pin - T10492- into fork on follower -1- and into hole -2- behind it in cylinder head.
– Loosen bolt -1- half a turn.
• Locking pin - T10492- -2- engaged.
– Lock crankshaft toothed belt pulley -1- in position using crankshaft stop - T10490- -2-.
• Pins of crankshaft stop - T10490- -2- must engage in threaded holes of toothed belt pulley -1-.
• It is essential that the torque for loosening and tightening the central bolts on camshaft and high-pressure pump is not transferred to the respective locking pin.
• Therefore, pull out locking pin for loosening and tightening the central bolt, and reinsert the locking pin afterwards if necessary.
– Pull out locking pin, and slightly loosen bolt for camshaft. Before loosening completely, insert locking pin back in.
– Loosen bolt -1- for camshaft pulley. To do this, use counterhold - T10172- -3- with adapter - T10172/11- -2-.
– Lock hub of high-pressure pump using locking pin - T10492-
-3-. To do this, insert locking pin - T10492- into fork -2- of hub
and into hole -1- behind it.
– Pull out locking pin - T10492- and slightly loosen nut for highpressure toothed belt pulley. Before loosening completely,
insert locking pin back in.
– Loosen nut -1- for high-pressure pump pulley by approx. 90°.
To do this, use counterhold - T10051- -2-.
Note
Different tensioning rollers -A or B- may be installed depending on the equipment. The adjustment jig -1- is the distinguishing feature. The tensioning roller -A- is not locked in position using
locking tool - T10265- . Instead, the angle driver 8mm - T10409- must be used for tensioning. Apart from that the procedure is identical.
– Loosen nut -1-.
– Turn eccentric of tensioning roller anti-clockwise in direction
of -arrow- using angle driver - T10264- -3- until tensioning roller can be locked with locking tool - T10265- -2-.
– Turn tensioning roller eccentric clockwise in direction of
-arrow- onto stop using angle driver - T10264- -3-.
– Tighten nut -1- hand-tight.
– If toothed belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen.
– Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.
Installing
Install in reverse order of removal, observing the following:
Adjusting valve timing
Prerequisites:
• For adjusting work on the toothed belt, the engine must be cold.
• When turning camshaft, crankshaft must be positioned so that no piston is positioned at TDC.
• Tensioning roller locked with locking tool - T10265- -2- and secured to right stop with nut -1-.
• Metal lug -arrow- of tensioning roller must engage in cast recess on cylinder head.
• Camshaft hub -2- locked with locking pin - T10492- -3-.
• Bolt fitted but not tightened.
• It should just be possible to turn camshaft pulley easily without axial movement.
• Bolt -1- loosened by half a turn and positioned in centre of elongated hole.
• Crankshaft locked in position with crankshaft stop - T10490- -2-.
• Hub -1- on high-pressure pump locked in place with locking pin - T10492- -3-.
• Nut fitted but not tightened.
• It should just be possible to turn high-pressure pump pulley easily without axial movement.
– Turn toothed belt sprocket of camshaft and toothed belt sprocket of high-pressure pump in their elongated holes clockwise as far as the stop.
– Fit toothed belt in sequence described:
1 - Crankshaft pulley
2 - Tensioning pulley
3 - Camshaft toothed belt pulley
4 - High-pressure pump toothed belt pulley
5 - Coolant pump toothed belt pulley
– Loosen nut -1- and remove locking tool - T10265- -2-.
• Metal lug of tensioning roller must remain engaged in cast recess on cylinder head.
• The locking bolt must not lie against upper stop of elongated hole after toothed belt has been tensioned.
– Check that bolt -1- is still located between centre of elongated hole and lower stop. If necessary, move position of camshaft sprocket one tooth in clockwise direction and fit toothed belt again.
– Using angle driver - T10264- -3- or angle driver 8mm -T10409- , carefully turn tensioning roller eccentric clockwise in direction of -arrow- until indicator -2- is in middle of gap in base plate.
• Make sure that nut -1- does not turn at same time.
– Hold tensioning roller in this position and tighten nut -1-.
– Place counterhold - T10172- -3- with adapter - T10172/11- -4- on toothed belt sprocket of camshaft.
– Push counterhold - T10172- -3- anti-clockwise in direction of -arrow- and maintain tension.
– Tighten bolt -1- and nut -2- to 10 Nm in this position.
Note
The high-pressure pump pulley can only be turned to a limited extent. It is therefore essential to ensure that the toothed belt pulley has not been turned to the limit after tensioning.
– Ensure that marking on high-pressure pump toothed belt pulley is not in alignment with locking pin - T10492- -1-. If necessary, move position of toothed belt pulley one tooth in clockwise direction and fit toothed belt again.
– Remove locking pin - T10492- and crankshaft stop - T10490- and check valve timing
Checking valve timing
• Only turn crankshaft in engine direction of rotation.
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in engine's direction of rotation until crankshaft is at a position shortly before TDC.
– Place crankshaft stop - T10490- -2- back on crankshaft toothed belt pulley -1-.
– Turn crankshaft in direction of engine rotation until pin of crankshaft stop engages in sealing flange whilst turning.
Adjustment fault through inaccurate TDC setting
– If crankshaft has been turned beyond TDC, turn crankshaft another 2 turns until it is just before TDC position again.
Then, while turning in this direction, lock crankshaft with crankshaft stop - T10490- -2-.
• It should be possible to lock the camshaft hub -2- with locking pin - T10492- -3-.
• It is very difficult to find the locking point of the high-pressure pump hub again. A minor deviation -arrow-, though, does not influence engine operation.
• The belt tensioner indicator -2- must be in the middle between tabs -1- and -3- of the base plate.
• The indicator -2- must not be offset relative to tab -1- by more than 6 mm -a- in direction of engine rotation.
If the conditions are fulfilled, continue with the valve timing correctly adjusted
If the conditions are not fulfilled, correct the valve timing
Correcting valve timing
– If the hub of the camshaft can not be locked in position, pull camshaft stop - T10490- back until the lug exposes the hole.
– Turn crankshaft back to slightly before TDC by turning it in opposite direction of engine rotation.
– Now turn crankshaft slowly in direction of engine rotation until camshaft hub can be locked in position.
– After locking, loosen bolts for toothed belt sprocket of camshaft.
Lug of crankshaft stop - T10490- must be to left of hole.
– Turn crankshaft in direction of engine rotation until pin of crankshaft stop engages in sealing flange whilst turning.
– Tighten bolts for toothed belt sprocket of camshaft to 20 Nm.
Lug of crankshaft stop - T10490- must be to right of hole.
– First, turn crankshaft a little in direction opposite to engine's direction of rotation.
– Turn crankshaft in engine's direction of rotation again until crankshaft stop pin engages in sealing flange whilst turning.
– Tighten bolts for toothed belt sprocket of camshaft to 20 Nm.
Procedure after adjusting valve timing correctly
– Remove locking pin - T10492- and crankshaft stop - T10490- .
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in engine's direction of rotation until crankshaft is at a position shortly before TDC.
– Check valve timing again
• It is essential that the torque for loosening and tightening the central bolts on camshaft and high-pressure pump is not transferred to the respective locking pin.
• Therefore, pull out locking pin for loosening and tightening the central bolt, and reinsert the locking pin afterwards if necessary.
– If camshaft hub can now be locked, tighten bolt -1- for camshaft toothed belt pulley to final torque using counterhold -T10172- -3- with adapter - T10172/11- -4-.
– Tighten nut -2- for high-pressure pump pulley to final torque using counterhold - T10051- .
– Check valve timing again
Specified torques
Assembly overview - toothed belt
Assembly overview - toothed belt cover
Assembly overview - assembly mountings
Assembly overview - radiator cowl and radiator fan
Removing toothed belt from camshaft
Torque wrench - V.A.G 1332-
Torque wrench - V.A.G 1331-
Counterhold tool - T10051-
Counterhold tool - T10172-
Pin - T10492-
Crankshaft stop - T10490-
Angled screwdriver - T10264-
Locking tool - T10265-
Angled screwdriver AF 8 - T10409-
Removing
– Remove upper part of toothed belt guard
– Remove vibration damper
• Only turn crankshaft in engine direction of rotation.
– Turn crankshaft by bolt for toothed belt pulley until camshaft toothed belt pulley is at TDC.
– Lock camshaft hub with locking pin - T10492- -3-. To do this, insert locking pin - T10492- into fork on follower -1- and into hole -2- behind it in cylinder head.
– Loosen bolt -1- half a turn.
– Lock crankshaft toothed belt pulley -1- in position with crankshaft stop - T10490- -2-.
• Pins of crankshaft stop - T10490- -2- must engage in threaded holes of toothed belt pulley -1-.
• Journal -arrow- of crankshaft stop - T10490- -2- must engage in hole in sealing flange.
• It is essential that the torque for loosening and tightening the central bolts on camshaft and high-pressure pump is not transferred to the respective locking pin.
• Therefore, pull out locking pin for loosening and tightening the central bolt, and reinsert the locking pin afterwards if necessary.
– Pull out locking pin, and slightly loosen bolt for camshaft. Before loosening completely, insert locking pin back in.
– Loosen bolt -1- for camshaft pulley. To do this, use counterhold - T10172- -3- with adapters -T10172/11- -2-.
– Lock hub of high-pressure pump using locking pin - T10492- -3-. To do this, insert locking pin - T10492- into fork -2- of hub and into hole -1- behind it in ancillary bracket.
– Loosen nut -1- for high-pressure pump pulley by approx. 90°.
To do this, use counterhold - T10051- -2-.
Note
The installed tensioning rollers -A and B- differ from each other.
The adjustment jig -1- is the distinguishing feature. The tensioning roller -A- is not locked in position using locking tool - T10265- .
Instead, the angle driver 8mm - T10409- must be used for tensioning. Apart from that the procedure is identical.
– Loosen nut -1-.
– Turn eccentric of tensioning roller anti-clockwise in direction of -arrow- using angle driver - T10264- -3- until tensioning roller can be locked with locking tool - T10265- -2-.
– Turn tensioning roller eccentric clockwise in direction of -arrow- onto stop using angle driver - T10264- -3-.
– Tighten nut -1- hand-tight.
– Take toothed belt off camshaft sprocket.
Assembly overview - toothed belt cover, toothed belt
Removing and installing toothed belt guard
Removing and installing toothed belt
Adjusting valve timing
Checking valve timing
Adjustment fault through inaccurate TDC setting
Removing toothed belt from camshaft
Assembly overview - toothed belt cover
1 - Toothed belt guard, Bottom
2 - Bolts. Qty. 4, 12 Nm
3 - Bolt, 12 Nm
4 - Toothed belt guard, On side
5 - Toothed belt guard, Top
6 - Bolt, 12 Nm
7 - Toothed belt guard, Rear
Assembly overview - toothed belt
1 - Bolt, Renew after removal, Do not additionally oil the thread and shoulder, 180 Nm +135°
2 - Crankshaft, Contact surface between toothed belt pulley and crankshaft must be free from oil, Can only be fitted in one position
3 - Nut, 20 Nm
4 - Idler roller
5 - Nut, Renew after removal, 20 Nm +45°
6 - Tensioning pulley
7 - Toothed belt, Before removing, mark direction of rotation with chalk or felt-tipped marker pen.
8 - Bolt, Do not additionally oil the thread and shoulder, 100 Nm
9 - Bolt, 9 Nm
10 - Crankshaft, Contact surface between sprocket and camshaft must be free of oil
11 - Follower, For camshaft.
12 - Stud, For tensioning roller, 16 Nm
13 - Bolt, 20 Nm
14 - Idler roller
15 - High-pressure pump
16 - Hub, Contact surface between hub and toothed belt sprocket must be free of oil
17 - Crankshaft, Contact surface between hub and toothed belt sprocket must be free of oil
18 - Nut, Do not additionally oil the thread and shoulder
19 - O-ring, Renew after removal, Moisten with coolant
20 - Coolant pump
21 - Bolt
22 - Stud, For idler roller, 16 Nm
Removing and installing upper toothed belt guard
Removing
– Release retaining tabs -2- and remove upper toothed belt guard -1-.
Installing
Install in reverse order of removal.
Removing and installing side toothed belt guard
Special tools and workshop equipment required
Torque wrench - V.A.G 1331-
– Remove upper part of toothed belt guard
– Unscrew bolt -1-.
– Remove side toothed belt guard -2-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
Assembly overview - toothed belt cover
Removing and installing lower toothed belt guard
Special tools and workshop equipment required
Torque wrench - V.A.G 1331-
Removing
Note: To simplify the manufacturing process in the production facilities the lower toothed belt guard is provided with a guide at bottom which engages in the sealing flange.
When removing the toothed belt guard with engine support installed, the guide in the toothed belt guard must be destroyed.
Bear in mind that there are different versions!
– Remove viscous fan holder
– Remove vibration damper
– If a toothed belt guard version which is about to be discontinued is fitted, drill a hole according to the following dimensions:
Dimension -a- = 10 mm
Diameter: 8 mm
– Insert a screwdriver through drilled hole and break off guide lug of toothed belt guard towards rear.
– If a more recent toothed belt guard version is fitted, insert screwdriver into slot in guide lug.
– Turn screwdriver in direction of -arrow- and break off guide lug.
– Remove bolts -1-.
• Locking lug -3- broken off.
– Remove lower toothed belt guard -2-.
Installing
Install in reverse order of removal, observing the following:
– If a new toothed belt guard is installed, the guide lug -arrowmust be cut off prior to installing.
– Fit toothed belt guard -1-. Make sure that dowel pin engages on hole in coolant pump -arrow-.
Specified torques
Assembly overview - toothed belt cover
Removing and installing rear toothed belt cover
Special tools and workshop equipment required
Torque wrench - V.A.G 1331-
Removing
– Remove coolant valve for cylinder head - N489-
– Unscrew bolt -1-.
– Pull out rear toothed belt cover -2- in direction of -arrow-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
Assembly overview - toothed belt cover
Removing and installing toothed belt
Torque wrench - V.A.G 1332-
Torque wrench - V.A.G 1331-
Counterhold tool - T10051-
Counterhold tool - T10172-
Pin - T10492-
Crankshaft stop - T10490-
Angled screwdriver - T10264-
Locking tool - T10265-
Angled screwdriver AF 8 - T10409-
Removing
– Remove upper part of toothed belt guard
– Remove viscous fan pulley holder
– Remove lower toothed belt guard
• Only turn crankshaft in engine direction of rotation.
– Turn crankshaft by bolt for crankshaft pulley until camshaft pulley is at TDC.
– Lock camshaft hub with locking pin - T10492- -3-. To do this, insert locking pin - T10492- into fork on follower -1- and into hole -2- behind it in cylinder head.
– Loosen bolt -1- half a turn.
• Locking pin - T10492- -2- engaged.
– Lock crankshaft toothed belt pulley -1- in position using crankshaft stop - T10490- -2-.
• Pins of crankshaft stop - T10490- -2- must engage in threaded holes of toothed belt pulley -1-.
• It is essential that the torque for loosening and tightening the central bolts on camshaft and high-pressure pump is not transferred to the respective locking pin.
• Therefore, pull out locking pin for loosening and tightening the central bolt, and reinsert the locking pin afterwards if necessary.
– Pull out locking pin, and slightly loosen bolt for camshaft. Before loosening completely, insert locking pin back in.
– Loosen bolt -1- for camshaft pulley. To do this, use counterhold - T10172- -3- with adapter - T10172/11- -2-.
– Lock hub of high-pressure pump using locking pin - T10492-
-3-. To do this, insert locking pin - T10492- into fork -2- of hub
and into hole -1- behind it.
– Pull out locking pin - T10492- and slightly loosen nut for highpressure toothed belt pulley. Before loosening completely,
insert locking pin back in.
– Loosen nut -1- for high-pressure pump pulley by approx. 90°.
To do this, use counterhold - T10051- -2-.
Note
Different tensioning rollers -A or B- may be installed depending on the equipment. The adjustment jig -1- is the distinguishing feature. The tensioning roller -A- is not locked in position using
locking tool - T10265- . Instead, the angle driver 8mm - T10409- must be used for tensioning. Apart from that the procedure is identical.
– Loosen nut -1-.
– Turn eccentric of tensioning roller anti-clockwise in direction
of -arrow- using angle driver - T10264- -3- until tensioning roller can be locked with locking tool - T10265- -2-.
– Turn tensioning roller eccentric clockwise in direction of
-arrow- onto stop using angle driver - T10264- -3-.
– Tighten nut -1- hand-tight.
– If toothed belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen.
– Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.
Installing
Install in reverse order of removal, observing the following:
Adjusting valve timing
Prerequisites:
• For adjusting work on the toothed belt, the engine must be cold.
• When turning camshaft, crankshaft must be positioned so that no piston is positioned at TDC.
• Tensioning roller locked with locking tool - T10265- -2- and secured to right stop with nut -1-.
• Metal lug -arrow- of tensioning roller must engage in cast recess on cylinder head.
• Camshaft hub -2- locked with locking pin - T10492- -3-.
• Bolt fitted but not tightened.
• It should just be possible to turn camshaft pulley easily without axial movement.
• Bolt -1- loosened by half a turn and positioned in centre of elongated hole.
• Crankshaft locked in position with crankshaft stop - T10490- -2-.
• Hub -1- on high-pressure pump locked in place with locking pin - T10492- -3-.
• Nut fitted but not tightened.
• It should just be possible to turn high-pressure pump pulley easily without axial movement.
– Turn toothed belt sprocket of camshaft and toothed belt sprocket of high-pressure pump in their elongated holes clockwise as far as the stop.
– Fit toothed belt in sequence described:
1 - Crankshaft pulley
2 - Tensioning pulley
3 - Camshaft toothed belt pulley
4 - High-pressure pump toothed belt pulley
5 - Coolant pump toothed belt pulley
– Loosen nut -1- and remove locking tool - T10265- -2-.
• Metal lug of tensioning roller must remain engaged in cast recess on cylinder head.
• The locking bolt must not lie against upper stop of elongated hole after toothed belt has been tensioned.
– Check that bolt -1- is still located between centre of elongated hole and lower stop. If necessary, move position of camshaft sprocket one tooth in clockwise direction and fit toothed belt again.
– Using angle driver - T10264- -3- or angle driver 8mm -T10409- , carefully turn tensioning roller eccentric clockwise in direction of -arrow- until indicator -2- is in middle of gap in base plate.
• Make sure that nut -1- does not turn at same time.
– Hold tensioning roller in this position and tighten nut -1-.
– Place counterhold - T10172- -3- with adapter - T10172/11- -4- on toothed belt sprocket of camshaft.
– Push counterhold - T10172- -3- anti-clockwise in direction of -arrow- and maintain tension.
– Tighten bolt -1- and nut -2- to 10 Nm in this position.
Note
The high-pressure pump pulley can only be turned to a limited extent. It is therefore essential to ensure that the toothed belt pulley has not been turned to the limit after tensioning.
– Ensure that marking on high-pressure pump toothed belt pulley is not in alignment with locking pin - T10492- -1-. If necessary, move position of toothed belt pulley one tooth in clockwise direction and fit toothed belt again.
– Remove locking pin - T10492- and crankshaft stop - T10490- and check valve timing
Checking valve timing
• Only turn crankshaft in engine direction of rotation.
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in engine's direction of rotation until crankshaft is at a position shortly before TDC.
– Place crankshaft stop - T10490- -2- back on crankshaft toothed belt pulley -1-.
– Turn crankshaft in direction of engine rotation until pin of crankshaft stop engages in sealing flange whilst turning.
Adjustment fault through inaccurate TDC setting
– If crankshaft has been turned beyond TDC, turn crankshaft another 2 turns until it is just before TDC position again.
Then, while turning in this direction, lock crankshaft with crankshaft stop - T10490- -2-.
• It should be possible to lock the camshaft hub -2- with locking pin - T10492- -3-.
• It is very difficult to find the locking point of the high-pressure pump hub again. A minor deviation -arrow-, though, does not influence engine operation.
• The belt tensioner indicator -2- must be in the middle between tabs -1- and -3- of the base plate.
• The indicator -2- must not be offset relative to tab -1- by more than 6 mm -a- in direction of engine rotation.
If the conditions are fulfilled, continue with the valve timing correctly adjusted
If the conditions are not fulfilled, correct the valve timing
Correcting valve timing
– If the hub of the camshaft can not be locked in position, pull camshaft stop - T10490- back until the lug exposes the hole.
– Turn crankshaft back to slightly before TDC by turning it in opposite direction of engine rotation.
– Now turn crankshaft slowly in direction of engine rotation until camshaft hub can be locked in position.
– After locking, loosen bolts for toothed belt sprocket of camshaft.
Lug of crankshaft stop - T10490- must be to left of hole.
– Turn crankshaft in direction of engine rotation until pin of crankshaft stop engages in sealing flange whilst turning.
– Tighten bolts for toothed belt sprocket of camshaft to 20 Nm.
Lug of crankshaft stop - T10490- must be to right of hole.
– First, turn crankshaft a little in direction opposite to engine's direction of rotation.
– Turn crankshaft in engine's direction of rotation again until crankshaft stop pin engages in sealing flange whilst turning.
– Tighten bolts for toothed belt sprocket of camshaft to 20 Nm.
Procedure after adjusting valve timing correctly
– Remove locking pin - T10492- and crankshaft stop - T10490- .
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in engine's direction of rotation until crankshaft is at a position shortly before TDC.
– Check valve timing again
• It is essential that the torque for loosening and tightening the central bolts on camshaft and high-pressure pump is not transferred to the respective locking pin.
• Therefore, pull out locking pin for loosening and tightening the central bolt, and reinsert the locking pin afterwards if necessary.
– If camshaft hub can now be locked, tighten bolt -1- for camshaft toothed belt pulley to final torque using counterhold -T10172- -3- with adapter - T10172/11- -4-.
– Tighten nut -2- for high-pressure pump pulley to final torque using counterhold - T10051- .
– Check valve timing again
Specified torques
Assembly overview - toothed belt
Assembly overview - toothed belt cover
Assembly overview - assembly mountings
Assembly overview - radiator cowl and radiator fan
Removing toothed belt from camshaft
Torque wrench - V.A.G 1332-
Torque wrench - V.A.G 1331-
Counterhold tool - T10051-
Counterhold tool - T10172-
Pin - T10492-
Crankshaft stop - T10490-
Angled screwdriver - T10264-
Locking tool - T10265-
Angled screwdriver AF 8 - T10409-
Removing
– Remove upper part of toothed belt guard
– Remove vibration damper
• Only turn crankshaft in engine direction of rotation.
– Turn crankshaft by bolt for toothed belt pulley until camshaft toothed belt pulley is at TDC.
– Lock camshaft hub with locking pin - T10492- -3-. To do this, insert locking pin - T10492- into fork on follower -1- and into hole -2- behind it in cylinder head.
– Loosen bolt -1- half a turn.
– Lock crankshaft toothed belt pulley -1- in position with crankshaft stop - T10490- -2-.
• Pins of crankshaft stop - T10490- -2- must engage in threaded holes of toothed belt pulley -1-.
• Journal -arrow- of crankshaft stop - T10490- -2- must engage in hole in sealing flange.
• It is essential that the torque for loosening and tightening the central bolts on camshaft and high-pressure pump is not transferred to the respective locking pin.
• Therefore, pull out locking pin for loosening and tightening the central bolt, and reinsert the locking pin afterwards if necessary.
– Pull out locking pin, and slightly loosen bolt for camshaft. Before loosening completely, insert locking pin back in.
– Loosen bolt -1- for camshaft pulley. To do this, use counterhold - T10172- -3- with adapters -T10172/11- -2-.
– Lock hub of high-pressure pump using locking pin - T10492- -3-. To do this, insert locking pin - T10492- into fork -2- of hub and into hole -1- behind it in ancillary bracket.
– Loosen nut -1- for high-pressure pump pulley by approx. 90°.
To do this, use counterhold - T10051- -2-.
Note
The installed tensioning rollers -A and B- differ from each other.
The adjustment jig -1- is the distinguishing feature. The tensioning roller -A- is not locked in position using locking tool - T10265- .
Instead, the angle driver 8mm - T10409- must be used for tensioning. Apart from that the procedure is identical.
– Loosen nut -1-.
– Turn eccentric of tensioning roller anti-clockwise in direction of -arrow- using angle driver - T10264- -3- until tensioning roller can be locked with locking tool - T10265- -2-.
– Turn tensioning roller eccentric clockwise in direction of -arrow- onto stop using angle driver - T10264- -3-.
– Tighten nut -1- hand-tight.
– Take toothed belt off camshaft sprocket.
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