Volkswagen Golf Variant / Jetta. Manual - part 379

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  377  378  379  380   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 379

 

 

screwdriver at the bolt heads -1- until it can be secured.

– Lock the high pressure fuel pump hub with the Diesel Injection

Pump Locking Pin - 3359- . To do this, slide the pin into the

opening outside the toothed belt sprocket.

– Rotate the camshaft sprocket and fuel high pressure pump

toothed belt sprocket clockwise in their oblong holes as far as

the stop.

– Install the toothed belt on the crankshaft toothed belt sprocket,

the tensioning roller, the camshaft sprocket, coolant pump

toothed belt sprocket and the fuel high pressure pump toothed

belt sprocket.

– Lay the belt on the last pulley.
– Loosen the tensioning roller nut and remove the Tensioning

Roller Locking Tool - T10265- .

Note

Make sure the tensioning roller is properly positioned in the rear

toothed belt guard -arrow-.

1. Cylinder Head    

99

with the Wrench - Tensioning Roller - T10264- until the indi‐

cator is located centrally in the base plate gap -2-.

• Make sure the nut -1- does not rotate with it.
– Hold the tensioning roller in this position and tighten the ten‐

sioning roller nut.

• Tightening specification -item 6- 

⇒ Item 6 (page 43)

 .

– Position the Counterhold - Kit - Multiple Use - T10172A- as

shown. Push the Counterhold - Multiple Use - T10172A- in the

direction of the arrow and hold the camshaft sprocket preten‐

sioned.

– Tighten the bolts -1- for the camshaft sprocket and the fuel

high pressure pump toothed belt sprocket in this position.

• Tightening specification: 20 Nm.
– Remove the Diesel Injection Pump Locking Pin - 3359- and

the Crankshaft Stop - T10100- or the Crankshaft Stop -

T10050- .

– Turn the crankshaft at least two additional turns in the direction

of engine rotation in direction of -arrow- and just before TDC

for cylinder 1.

– Position the Crankshaft Stop - T10100- or the Crankshaft Stop

- T10050- on the crankshaft toothed belt sprocket again.

– Now rotate the crankshaft in the direction of engine rotation

until the crankshaft stop pin -arrow- engages in the sealing

flange from the rotational movement.

100

In the following check, only the camshaft and crankshaft are se‐

cured. The high pressure fuel pump hub mounting point is very

difficult to recover. A small variance -arrow- does not affect engine

operation.

– Check if:
• The camshaft hub can be locked with the Diesel Injection

Pump Locking Pin - 3359- .

• The tensioning roller indicator points to the center or maximum

5 mm to the right of the gap in the base plate.

If the Camshaft Hub Cannot Be Secured:
– Pull the Crankshaft Stop - T10100- or the Crankshaft Stop -

T10050- toward the back until the pin opens the hole.

– Rotate the crankshaft opposite the direction of engine rotation

until it is slightly past TDC.

– Now rotate the crankshaft slowly in the direction of engine ro‐

tation until the camshaft hub can be secured.

– After securing, loosen the bolts on the camshaft toothed belt

sprocket.

If the Crankshaft Stop - T10100- or the Crankshaft Stop - T10050-

Pin Is to the Left of the Hole:

– Turn the crankshaft in direction of engine rotation until the

crankshaft stop tab engages the sealing flange.

– Tighten the camshaft toothed belt sprocket bolts.
• Tightening specification: 20 Nm.
If the Crankshaft Stop - T10100- or the Crankshaft Stop - T10050-

Pin is to the Right of the Hole:
– Rotate the crankshaft slightly opposite the direction of engine

rotation.

– Now turn the crankshaft in the direction of engine rotation until

the crankshaft stop pin engages the sealing flange.

– Tighten the camshaft toothed belt sprocket bolts.
• Tightening specification: 20 Nm.
Continuation
– Remove the Diesel Injection Pump Locking Pin - 3359- and

the Crankshaft Stop - T10100- or the Crankshaft Stop -

T10050- .

– Turn the crankshaft at least two additional turns in the direction

of engine rotation and just before TDC for cylinder 1.

– Check again.
The Camshaft Hub Can Now Be Secured:
– Tighten the bolts as follows:

1. Cylinder Head    

101

1

/8 (45 °) additional turn.

Counterhold with Counterhold - Kit - Multiple Use - T10172-

and Counterhold - Kit - Adapter 4 - T10172/4- .

• Fuel high pressure pump toothed belt sprocket: 

1

/4 (90 °) ad‐

ditional turn. Counterhold with Counterhold - Kit - Multiple Use

- T10172- and Counterhold - Kit - Adapter 8 - T10172/8- .

– Install the toothed belt guard lower section and center section

-arrows-.

• Tightening specification -item 27- 

⇒ Item 27 (page 44)

 .

– Install the belt pulley/vibration damper.
• Tightening specification -item 28- 

⇒ Item 28 (page 44)

 .

– Install the ribbed belt. Refer to

⇒ “1.4 Ribbed Belt, Removing and Installing”, page 47

 .

– Install the toothed belt guard upper section.

102

 

 

 

 

 

 

 

Content   ..  377  378  379  380   ..