Elements of a gear-belt drive of a 5-cylinder engine (camshaft drive)
1 toothed belt
2 Camshaft gear
3 Tension roller
4 Rear timing belt cover
5 Coolant pump
6 Interlayer
7 Crankshaft gear
8 Bypass roller
9 Vibration damper
1Crankshaft center bolt.
Checking and tensioning the camshaft timing belt
Remove the toothed belt guard cover.
Push the toothed belt between the camshaft and pump gear with a plastic hammer.
Release the spring on the VW 21 tester by turning the handle. Place the instrument between the camshaft and the pump so that the toothed belt lies between the skids and the measuring tip of the instrument.
Preliminarily pull the device by the handle to the scale value 12-13. At the same time, a steel tongue protrudes from the side of the measuring device, on which a white mark is located, which should align with the edge of the device. Otherwise, adjustment of the toothed belt is necessary.
Install the tester, and then set the scale value of the instrument to 12-13.
After unscrewing the mounting bolt, turn the tension roller until the white perpendicular line on the tongue of the device is set against its body.
Tighten roller nut to 45 Nm.
Turn the crankshaft one revolution, repeat the measurements.
Fit the top cover of the toothed belt housing.
Check the start of the injection pump fuel supply.
Attention. If a test tool is not available, check the tension by turning the toothed belt with thumb and forefinger.
Replacing a toothed belt with an ox high-pressure fuel pump
Withdrawal
Raise the vehicle and remove the engine compartment inner guide cover.
Lower the vehicle and remove the hood latch and front bumper
On the right side of the vehicle, remove the lined casing and radiator mount.
On the left side, also unscrew the radiator mount and air duct.
Move the radiator forward and support it with a bar.
After loosening the tension, remove the V-belt.
Loosen the bolts and remove the cylinder head cover.
Remove the injection pump toothed belt guard from behind the cylinder head.
Remove the camshaft timing belt guard from the front.
Mark the direction of rotation of the toothed belt (clockwise).
Set cylinder 1 to TDC. For this you need:
- Set transmission to neutral position.
- Tighten the handbrake.
- Turn the crankshaft by the central bolt until the marks in the clutch housing window and the marks on the injection pump pulley match.
- If the marks do not match, then it is necessary to turn the crankshaft one more turn.
Engine 2.4L: lock the gear wheel of the high-pressure fuel pump with the help of a rod.
Engine 2.5L: loosen the lock nut of the toothed belt tensioner pulley, remove the spring (1).
While holding the camshaft gear with the tool, unscrew the mounting bolt and remove the gear and toothed belt.
Using a special block, lock the camshaft so that it cannot turn.
After loosening the camshaft timing belt tensioner pulley, remove the timing belt from the camshaft timing gear.
Using the special tool, unscrew the center bolt of the vibration damper.
Loosen the bolts and remove the vibration damper.
Having unscrewed the bolts securing the lower casing, remove the casing and toothed belt from the gear wheel.
Installation
Check the alignment of the installation marks.
Secure the camshaft against rotation with a block.
Loosen the camshaft gear bolt.
In the hole in the rear casing of the toothed belt, insert the bit into the toothed wheel until it stops and hitting the bit, loosen the fit of the camshaft gear.
Fit the camshaft timing belts without changing their direction of rotation.
After tensioning the toothed belt, tighten the tension roller nut with a force of 45 Nm.
Tighten the camshaft drive wheel bolt to 50 Nm.
Remove adjuster bar.
Loosen the camshaft drive wheel bolt half a turn. If required, i.e. loosen the camshaft drive wheel.
Set the piston of the first cylinder to the TDC position.
Tighten the camshaft gear bolt.
Rotate the crankshaft two turns. Drive the toothed belt down with a plastic hammer in the area: camshaft gear - injection pump gear and check the toothed belt tension again. If necessary, repeat the tension again.
From the rear of the engine, put on the toothed belt and the gear wheel of the injection pump, then tighten the central wheel bolt with a force of 50 Nm. Then again unscrew the bolt by half a turn. In this case, the gear wheel must be turned by hand.
Engine 2.4L: check the tension of the injection pump drive timing belt and, if necessary, adjust the tension by loosening the three injection pump mounting bolts.
Engine 2.5L: Putting on the toothed belt, install the tensioner spring.
- Loosen the idler pulley nut one turn. In this case, the tension roller must be pressed against the toothed belt.
- Install the toothed belt in its place by turning the crankshaft of the engine for this half a turn.
- Tighten the tension roller nut.
Install the bottom toothed belt guard.
After installing the tool, tighten the center bolt of the vibration damper.
Further assembly is carried out in the reverse order.
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