Volkswagen Golf / Golf Plus. Manual - part 304

 

  Index      Volkswagen     Volkswagen Golf (2004) / Golf Plus (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  302  303  304  305   ..

 

 

Volkswagen Golf / Golf Plus. Manual - part 304

 

 

marking at 1 o'clock
Vehicles with round crankshaft belt pulley
– Turn crankshaft to TDC No. 1 cylinder.

Note

Turn crankshaft until marking on crankshaft pulley and tooth seg‐

ment of camshaft pulley is on top. The marking on the rear toothed

belt guard must line up with the marking on the camshaft sender

wheel -arrow-.

– Lock hub using locking pin -3359- . To do this, slide locking

pin through the free elongated hole on left into hole in cylinder

head.

– Lock crankshaft toothed belt pulley with crankshaft stop -

T10050- . To do this, push crankshaft stop into teeth of belt

pulley from face side.

Note

The marks on the crankshaft toothed belt pulley and the crank‐

shaft stop must align. When doing this, the pin of the crankshaft

stop must insert in the drilling of the sealing flange.

Vehicles with oval crankshaft belt pulley
– Turn crankshaft to TDC No. 1 cylinder.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

54

     Rep. Gr.15 - Cylinder head, valve gear

 

ment of camshaft pulley is on top. The marking on the rear toothed

belt guard must align with the marking on the camshaft sender

wheel -arrow-.

– Lock hub using locking pin -3359- . To do this, slide locking

pin through the free elongated hole on left into hole in cylinder

head.

– Lock crankshaft toothed belt pulley with crankshaft stop -

T10100- . To do this, push crankshaft stop into teeth of toothed

belt pulley from its face side.

Note

The marks on the crankshaft toothed belt pulley and the crank‐

shaft stop must align. At the same time, the crankshaft stop pin

must engage in the drilling in the sealing flange.

Continuation for all vehicles
– Mark direction of rotation of toothed belt.

– Loosen securing bolts -1- of camshaft toothed belt pulley until

camshaft pulley can be moved within the elongated holes.

– Loosen tensioning roller securing nut.

– Turn pin wrench -T10020- anti-clockwise until toothed belt

tensioning roller can be locked with locking pin -T10115- .

Note

A hexagon key can be used to tension or relieve tension on the

tensioner.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Cylinder head    

55

 

– Remove toothed belt first from coolant pump and then from

remaining pulleys.

Installing
• Camshaft locked with locking pin -3359- .
• The crankshaft is locked with crankshaft stop -T10050- or

crankshaft stop -T10100- .

• Tensioning roller locked with locking pin -T10115- and se‐

cured to right stop.

Note

Adjustment work on toothed belts must be performed only on cold

engines, as the indicator position on the tensioning element varies

depending on the engine temperature.

– Turn camshaft pulley in its elongated holes to centre position

-arrows-.

– Fit toothed belt onto crankshaft toothed belt pulley, tensioning

roller, camshaft toothed belt pulley and idler roller.

– Then fit toothed belt on coolant pump toothed belt pulley.

Note

Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.

– Loosen tensioning roller securing nut and pull out locking pin

-T10115- .

– Now carefully turn tensioning roller clockwise using pin wrench

-T10020- until indicator is in middle of gap in the base plate

-arrow-.

Ensure that securing nut does not turn as well.
– Hold tensioning roller in this position and tighten tensioning

roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

56

     Rep. Gr.15 - Cylinder head, valve gear

 

camshaft toothed belt pulley under tension.

– In this position, tighten camshaft toothed belt pulley securing

bolts -1- to 25 Nm.

– Remove locking pin -3359- and crankshaft stop -T10050- .
– Turn crankshaft two rotations in engine direction of rotation

until crankshaft is just before TDC No. 1 cylinder.

Vehicles with round crankshaft belt pulley

– Lock hub with locking pin -3359- whilst turning engine in di‐

rection of rotation.

– Check whether crankshaft can be locked with crankshaft stop

-T10050- .

If crankshaft cannot be locked

– Loosen securing bolts -1- for camshaft toothed belt pulley.

– Turn crankshaft slightly against engine direction of rotation

until the pin of the crankshaft stop is positioned just before the

hole in the sealing flange -arrow-.

– Now turn crankshaft in engine direction of rotation until crank‐

shaft stop pin engages in sealing flange whilst turning.

Vehicles with oval crankshaft belt pulley

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Cylinder head    

57

 

 

 

 

 

 

 

 

Content   ..  302  303  304  305   ..