Engine 1.9-I-TDI-110 hp
All operations for removing and installing a toothed belt on a diesel engine (1.9-I-TDI-110 hp) are similar to the operations for removing and installing a toothed belt on gasoline engines 1.8-I (125/150 HP). The rest of this section describes operations that are specific to 1.9-I-TDI engines only (110 HP).
Remove poly V-belt.
Remove the top casing of a gear belt.
Turn the crankshaft of the engine to the position of setting the piston of the first cylinder to TDC.
To block the camshaft in the TDC position of the piston of the first cylinder in the compression stroke, it is necessary to use a special adjusting ruler 2065-A or a tool made independently according to the dimensions shown in Figure 2.29.
Install the locking tool into the groove in the end of the camshaft (see fig. 2.30).
With the adjusting ruler installed in the camshaft, rotate the camshaft (turning the crankshaft clockwise) so that the adjusting ruler with one side is pressed against the surface of the cylinder head. Using a feeler gauge blade, measure the gap between the second end of the shim and the cylinder head. Turn the camshaft slightly back and on both sides between the adjusting ruler and the cylinder head, install two probes with a thickness equal to half of the previously measured clearance.
Through the hole in the clutch housing, check that the TDC mark on the flywheel is aligned with the pointer (see fig. 2.31).
Insert the AUDI-2064 locking pin through the high pressure fuel pump pulley mounting hole into the hole in the bracket behind the fuel pump pulley (see fig. 2.32). Instead of the locking pin, a drill shank with a diameter of 15 mm and a length of 36 mm can be used.
Unscrew the guide roller.
Remove the crankshaft pulley and lower toothed belt cover in the same way as for the 1.8-I engine.
Release the tension roller, loosen the tension and remove the toothed belt. To reinstall the toothed belt, note the direction of rotation.
Loosen the camshaft pulley bolt half a turn, while holding the camshaft from turning with the second wrench. Remove the timing belt pulley from the camshaft alignment cone using a drift through the hole in the rear timing belt housing (see fig. 2.33).
Completely unscrew the bolt and remove the toothed belt pulley from the camshaft.
Install the toothed belt guide pulley and secure it with the bolt, tightening it to 25 Nm.
Install the toothed belt on the crankshaft pulleys, fuel pump, camshaft and lastly on the tensioner pulley.
Install the pulley with the toothed belt put on it on the camshaft, while the pulley should rotate on the shaft.
Remove the high pressure fuel pump blocking pin.
Wrench (e.g. HAZET 2587) turn the toothed belt tensioner clockwise until the marks on the pulley and tensioner hub are aligned (see fig. 2.34).
Tighten the tension roller mounting nut to 20 Nm.
Check again that the TDC mark on the flywheel is aligned with the pointer.
Tighten the camshaft pulley bolt to 45 Nm, while holding the camshaft from turning with the second wrench.
Remove the adjusting ruler from the groove of the camshaft.
Remove the high pressure fuel pump blocking pin.
Turn the engine crankshaft two revolutions in the normal direction of rotation and reset the No. 1 cylinder to TDC on the compression stroke. Check that the marks on the pulley and hub of the tensioner are aligned (see fig. 2.34). Check and, if necessary, readjust the toothed belt tension.
Install the toothed belt guard, belt pulley (vibration damper), poly V-belt tensioner and cylinder head cover.
Install poly V-belt.
Check the injection timing of the high pressure fuel pump.
Engine 1.9-I-TDI-115/130 l. With.
This section only covers operations related to the 115/130 HP engine. Operations concerning all engines are given in the section describing the description of gasoline engines 1.8-I (125/150 HP).
Unscrew the two bolts and remove the V-ribbed belt tensioner.
Engine 115 hp Unscrew the pipes of the cooling system fixed on the casing of the toothed belt and move them to the side.
Remove the top casing of a gear belt.
Unscrew the solenoid valve and move it to the side.
Turn the engine crankshaft to the position of the installation of the piston of the first cylinder at TDC, while the groove between the two projections on the rear plate of the camshaft pulley must be aligned with the 4Z mark (see fig. 2.35).
Install the AUDI-3359 fixing rod in the hole and fix the camshaft pulley from turning. A drill shank with a diameter of 6 mm can be used instead of the fixing rod.
Using special tool T10050, fix the crankshaft timing belt pulley (see fig. 2.36). Pulley marks 2 (pic. 2.36) and special tool 1 must be aligned.
Holding the eccentric of the tension roller with a special wrench 3387, unscrew the nut one turn and turn the eccentric clockwise until it stops (see fig. 2.37).
Push down on lever 1 (pic. 2.37) tension roller and insert the blocking plate T10008 which will fix the toothed belt tensioner.
Using a special key 3387, turn the eccentric clockwise until it stops and release the tension roller.
Unscrew the guide roller and remove the toothed belt.
Install and screw the tension roller.
Using a special key 3387, turn the tension roller eccentric clockwise until it stops.
Install the timing belt onto the camshaft pulley, idler pulley, crankshaft pulley and water pump pulley.
Turn the tension roller eccentric counterclockwise until it stops and remove the T10008 blocking plate.
Adjust the toothed belt tension. To do this, use a special key 3387 to turn the eccentric clockwise until a drill shank with a diameter of 4 mm can be inserted between the lever and the body (see fig. 2.38).
While holding the tension roller in this position, tighten the nut 1 (pic. 2.38) fastening the roller with a torque of 25 Nm.
Remove dowel pin 3359 and special tool T10050 which fixed the camshaft and crankshaft pulleys.
Turn the engine crankshaft two revolutions in the normal direction of rotation, set the piston of the first cylinder to TDC on the compression stroke and check the dimension a (pic. 2.38). If the size differs from the required one, re-adjust and tighten the tension roller eccentric fastening nut to 30 Nm.
Install the toothed belt guard.
Screw on the crankshaft pulley and tighten its fastening bolts to 10 Nm. Before screwing in the bolts, apply AUDI D000600A2 blocking compound to the bolt threads.
Screw on the solenoid valve.
Establish and fix branch pipes of system of cooling on a casing of a gear belt.
Install and screw the V-ribbed belt tensioner.
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