2. To access the components, remove the accessory straps as described in paragraph 6.
Tensioner
Withdrawal
3. As described in the relevant paragraphs paragraphs 2 and 4, set the engine to the TDC of the first cylinder and remove the upper part of the outer timing belt cover.
4. Loosen the fastening nut on the hub of the tensioner pulley and allow the assembly to turn counterclockwise, relieving the timing belt tension. Loosen the nut and remove the washer.
5. Remove the tensioner from the mounting stud.
6. Wipe the tensioner, but do not use any solvents, so as not to spoil the bearing. Turn the tensioner pulley on the hub by hand. There should be no seizure or bearing noise. A defective or worn tensioner is replaced with a new one.
Installation
7. Slide the tensioner onto the mounting stud.
8. Install the washer and tighten the tensioner nut - do not fully tighten at this stage.
9. As described in paragraph 4, install and tension the timing belt.
10. Install the timing belt covers as described in paragraph 4.
11. Install accessory straps as described in paragraph 6. Connect the battery as described in chapter 5A.
Camshaft sprocket
Withdrawal
12. Set the engine to TDC as described in paragraph 2 and remove the timing belt top cover as described in paragraph 4.
13. Remove the valve cover as described in paragraph 7.
14. Loosen the tensioner hub nut and allow the assembly to turn counterclockwise, relieving belt tension. Slide the belt off the camshaft sprocket.
15. When loosening the camshaft sprocket bolt, it must be held motionless; if the Audi/VW tool is not available, you can make a homemade one. To fix the camshaft, do not use the fixing film before loosening the bolt, it must be removed so as not to bend.
16. While holding the sprocket from turning with a homemade tool, loosen its fastening bolt by half a turn. Release the sprocket from its tapered fit by tapping it through a punch inserted into the hole in the rear timing belt cover.
17. Remove the bolt and remove the sprocket from the camshaft (pic. 5.17).
18. After removing the sprocket, check the condition of the camshaft oil seal - if necessary, replace it as described in paragraph 8.
19. Wipe dirty mating surfaces of the sprocket and camshaft.
Installation
20. Install the sprocket on the shaft and tighten the bolt of its fastening, tightening only "by hand".
21. As described in paragraph 2 and 4, set the engine to the TDC of the first cylinder. Install the timing belt and tension it.
22. Install the timing belt top cover and valve cover. Install the accessory belts as described in paragraph 6. Connect the battery as described in chapter 5A.
Crankshaft sprocket
Withdrawal
23. Remove the upper and lower outer timing belt covers and the belt itself, as described in paragraph 4. If the belt is to be reinstalled, mark the direction of rotation on it.
24. To loosen the mounting bolt, the crankshaft sprocket must be held motionless. If there is no access to the Audi/WV tool, remove the starter and ask an assistant to lock the flywheel with a screwdriver, resting it on the crown teeth.
25. Turn away a bolt, remove a washer and an asterisk.
26. After removing the sprocket, check the condition of the oil seal - if necessary, replace it as described in paragraph 10.
27. Wipe mating surfaces of shaft and sprocket unclean.
Installation
28. Put the sprocket on the crankshaft, aligning the protrusion with the crankshaft slot. Insert the mounting bolt and tighten to the specified torque for stage 1 while holding the crankshaft stationary using the method used in removal. Tighten the bolt to the prescribed angle (Figure 5.28, a-c).
29. Make sure that the engine is still set to TDC of the first cylinder (cm. paragraphs 2 and 4). Install and tension the timing belt. Install the outer timing belt covers as described in paragraph 6 and connect the battery as described in chapter 5A.
Auxiliary shaft sprocket
Withdrawal
30. Remove the upper and lower timing belt covers and the belt itself, as described in paragraph 4. If the belt is to be reinstalled, mark the direction of rotation on the belt.
31. To loosen the bolt, the intermediate wheel sprocket must be held motionless. If no Audi/VW tool is available, make a homemade one as described in the relevant subparagraph for the camshaft sprocket. You can block the sprocket by inserting an extension socket into the sprocket hole (pic. 5.31).
32. Loosen and unscrew the sprocket mounting bolt and remove it from the shaft. Remove the key from the slot in the shaft.
33. After removing the sprocket, check the condition of the shaft seal. If necessary, replace it as described in paragraph 9.
34. Wipe the mating surfaces of the sprocket and shaft clean.
Installation
35. Install the key on the shaft with the flat side facing out. Slide the sprocket onto the shaft, aligning it with the key.
36. Screw in and tighten the sprocket bolt to the specified torque. Hold the sprocket from turning using the method used for removal.
37. Make sure that the engine is still set to the TDC of the first cylinder (cm. paragraphs 2 and 4). Install and tension the timing belt. Install the outer timing belt covers as described in paragraph 6 and connect the battery as described in chapter 5A.
Injection pump sprocket
38. The procedure is described in chapter 4B.
Visitor comments