Volkswagen Golf / Golf Plus. Manual - part 306

 

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Volkswagen Golf / Golf Plus. Manual - part 306

 

 

– Unscrew bracket -3- for fuel filter.

– Disconnect electrical connector on coolant expansion tank

-1-.

– Remove coolant expansion tank, coolant hoses remain con‐

nected. Place it on engine.

– Remove poly V-belt 

⇒ page 13

 .

– Remove tensioning element for poly V-belt.

– Remove upper toothed belt guard, to do this, loosen retaining

clips -arrows-.

– Remove front right wheel housing liner.
– Remove belt pulley with vibration damper.
– Remove lower and centre parts of toothed belt guard.
– Turn crankshaft to TDC No. 1 cylinder.

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

62

     Rep. Gr.15 - Cylinder head, valve gear

 

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 -

T10100- . 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.

– 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 -1-.
– Turn eccentric of tensioning roller anti-clockwise -arrow- using

socket -T10264- , until the tensioning roller can be locked with

locking tool -T10265- .

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

1. Cylinder head    

63

 

– Remove toothed belt first from coolant pump and then from

remaining toothed belt pulleys.

Installing
• Camshaft locked with locking pin -3359- .
• Crankshaft locked with crankshaft stop -T10100- .
• Tensioning roller locked with locking pin -T10265- and se‐

cured to right stop with securing nut.

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-.

– Guide toothed belt through gap between engine support and

engine.

– 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-.

– Remove locking pin -T10265- from tensioning roller.
– Loosen tensioning roller securing nut -1-.

– Turn eccentric of tensioning roller clockwise -arrow- using

special wrench, long reach -T10264- until indicator -2- is in

middle of gap in base plate.

Note

Ensure that securing nut does not turn as well.

– Hold tensioning roller in this position and tighten tensioning

roller nut to 20 Nm + 45° (

1

/8 turn).

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

64

     Rep. Gr.15 - Cylinder head, valve gear

 

side, by pressing in -direction of arrow-.

– Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.
– Remove locking pin -3359- and crankshaft stop -T10100- .
– Turn crankshaft two rotations in engine direction of rotation

until the crankshaft is just before TDC again.

– Lock hub of camshaft with locking pin -3359- whilst turning

engine in direction of rotation.

– Check whether crankshaft can be locked with crankshaft stop

-T10100- .

If crankshaft cannot be locked

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

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

1. Cylinder head    

65

 

 

 

 

 

 

 

 

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