Auto Manual of VW Passat B5

2.4.1. A gear belt

THE GENERAL DATA

The tension of a gear belt in four-cylinder petrol engines is carried out by a roller of the automatic mechanism of a tension which supports an optimum tension of a belt therefore service life and smoothness of a course of a gear belt increases.

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The prevention

On engines with various codes various rollers of the automatic mechanism of a tension of a gear belt are established.

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Removal

Combination of adjusting labels


Removal of a gear belt is made on the engine which temperature should be more than 30 S.Pri of necessity warm up the engine.

PERFORMANCE ORDER

1. Remove auxiliary клиновой a belt. 2. Unscrew the tension mechanism поликлинового auxiliary приводного a belt. 3. Remove the top casing of a gear belt. 4. If the gear belt is repeatedly established, using a marker or a paint, note a direction of rotation of a gear belt. If to look from a forward part of the engine, engine pulleys rotate clockwise. 5. Turn the engine so that the piston of the first cylinder was established in the top dead point. To turn a cranked shaft of the engine it is possible in the next ways:   – Lift a forward part of the car and fix on supports. Include the fifth transfer and tighten a manual brake. Keeping one forward wheel from проворачивания, manually turn the second forward wheel. Thus the cranked shaft of the engine will be turned;   – Establish the car on an equal horizontal platform, then include the fifth transfer and manually move the car forward or back;   – Establish a transmission in neutral position and tighten a manual brake. Using a wrench, for a bolt of fastening of a pulley of a cranked shaft turn a cranked shaft of the engine. The prevention Do not turn a cranked shaft of the engine for a bolt of fastening of a pulley of a camshaft, as in this case loading on a gear belt the maximum. 6. Turn a cranked shaft of the engine until the label on a camshaft pulley will not be combined with index ВМТ on a cover of a head of the block of cylinders (fig. Combination of adjusting labels see. Check up that the label on a pulley of a cranked shaft was combined with the index on the bottom casing of a gear belt. At combination of labels with indexes the piston of the first cylinder is in ВМТ in a compression step.

Engine ADP

Combination of an adjusting label of a pulley of a camshaft with the index and labels on pulleys of cranked and intermediate shaft on engine ADP at installation of the piston of the first cylinder in ВМТ


On engine ADP the distributor of ignition with a drive from an intermediate shaft is established. If the label on a camshaft pulley is combined with the index labels on pulleys of cranked and intermediate shaft should be combined.

PERFORMANCE ORDER

1. Keeping from проворачивания a pulley of a cranked shaft, unscrew four bolts, крепящие a pulley to a cranked shaft. Remove a pulley of a cranked shaft. 2. Unscrew screws and remove the bottom casing of a gear belt.

Engines AEB, ADP

PERFORMANCE ORDER

Ослабьте a bolt of fastening tension рлика a gear belt.

Engine AHL

PERFORMANCE ORDER

Ослабьте a nut of fastening of a tension roller of a gear belt.

Engine ADR

Tension roller of a gear belt on engine ADR

1 – a tension roller, 2 – an aperture in the case of the piston, 3 – a bolt

PERFORMANCE ORDER

1. Using 8-millimetric шестигранник, slowly turn counter-clockwise a tension roller of a gear belt before combination of apertures (2) in the piston and the case (the Tension roller of a gear belt fig. see engine ADR). Insert into the combined aperture a steel core or a shaft of a drill of the corresponding diameter. The prevention In work of an element of a tension of a gear belt the principle hydraulic успокоителя is used and it can be compressed only at the temperature exceeding 30 S.Ne unscrew a bolt (3), the Tension roller of a gear belt fig. see engine ADR. 2. Remove a gear belt from engine pulleys. The prevention Do not bend sharply gear belt as while in service the gear belt in a place of a sharp excess can be broken off that will lead to engine damage. After removal of a gear belt do not change position of pulleys of a gear belt. If after removal of a gear belt to turn a cranked shaft of the engine, there will be an impact of pistons to valves therefore they will be damaged and serious repair of the engine is required. Note position of a pulley of a cranked shaft for what a paint put labels on a pulley and the block of cylinders of the engine. If necessary it is possible to turn a cranked shaft of the engine on 90 on hour or counter-clockwise. Check up a gear belt on deterioration, stratification or замасливание. If on a gear belt there are oil traces, before installation of a new belt find a source of leak of oil and eliminate it.

Survey

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The prevention

Do not overwind and do not bend a gear belt.

Exclude hit on a gear belt of the oil, cooling liquid or fuel.

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If has occurred выкрашивание teeths of a gear belt, probably, the distributor of ignition, the water pump, the oil pump or a camshaft are jammed.

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The prevention

If there was a rupture of a gear belt on the working engine, probably that there was an impact of pistons about the valve therefore the valve can be погнуты. Check up backlashes of valves. On погнутых valves клапанные backlashes will be much more demanded.

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If there is a considerable deterioration, cracks or stratification on an external surface of a gear belt, check up a condition of racetracks of single pulleys.

Deterioration of one party of a belt specifies on несоосность pulleys of a gear belt. Check up directing a gear belt and alignment of pulleys of a gear belt.

In the presence of any defects on a gear belt it is necessary to replace it. Periodic replacement of a gear belt should be made through 100 000 km of run of the car.

Installation

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The prevention

Installation and tension of a gear belt make on the cold engine.

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PERFORMANCE ORDER

1. Establish a gear belt on pulleys of cranked and intermediate shaft. The prevention At repeated installation of a gear belt establish it so that the marksman on a belt, put before belt removal, coincided with a direction of rotation of pulleys of the engine. If after installation the gear belt rotates in an opposite side, probably, occurrence of cracks on a belt and engine breakage. 2. Establish into place and fix bolts the bottom casing of a gear belt. 3. Establish a belt pulley of a cranked shaft and fix its bolts, having tightened their moment of 25 Nanometers. Keep in mind that the pulley is established only in one position. 4. Check up that labels of pulleys of distributive and cranked shaft are combined with indexes. 5. Put on a gear belt a camshaft pulley.

Engines AEB, ADP

Elements of a tension of a gear belt on engines AEV, ADP

And – the holder, In – a wrench 1 – a shoulder of the holder, 2 – the piston, 3 – a wrench established on the screw

The control sizes for check of correctness of a tension of a gear belt on engines AEV, ADP, ADR

PERFORMANCE ORDER

1. Using a wrench () or special key HAZET 2587 turn clockwise the holder () a tension roller of a gear belt so that the piston (1) left against the stop, and the piston (2) has risen on 1 mm over the case. Keeping in this position a tension roller of a gear belt, tighten the screw (3) moment of 25 Nanometers, Elements of a tension of a gear belt fig. see engines AEV, ADP. 2. Turn a cranked shaft of the engine on 2 complete revolutions clockwise and check up that labels on pulleys of cranked and distributive shaft were combined with indexes. 3. Check up an arrangement of elements of the mechanism of a tension of a gear belt. The size And should be combined with the top edge of the piston. The size D should be in limits of 25-29 mm (the Control sizes for check of correctness of a tension of a gear belt fig. see engines AEV, ADP, ADR). In this case the tension of a gear belt is correctly adjusted. If the top edge of the piston is in limits of the size B or With, it is necessary to make repeated adjustment of a tension of a gear belt, and also to check up a condition of a gear belt and a tension roller. If the top end face of the piston settles down in area In or the size D more than 29 mm, it is necessary to adjust position of a tension roller of a gear belt. If the top end face of the piston settles down in area With, it is necessary to adjust repeatedly position of a tension roller of a gear belt, and also to check up a condition of a gear belt together with a tension roller. If necessary establish a new gear belt and a tension roller.

Engine ADR

PERFORMANCE ORDER

1. Using 8-millimetric шестигранный a key, turn a tension roller of a gear belt counter-clockwise and take from an aperture of the piston a steel core or a drill. Release a tension roller and remove шестигранный a key. Do not rotate a bolt (3), the Tension roller of a gear belt fig. see engine ADR. 2. Turn a cranked shaft of the engine on 2 complete revolutions clockwise and check up that labels on pulleys of cranked and distributive shaft were combined with indexes. 3. Check up an arrangement of elements of the mechanism of a tension of a gear belt. The size And should be combined with the top edge of the piston. The size D should be in limits of 25-29 mm (the Control sizes for check of correctness of a tension of a gear belt fig. see engines AEV, ADP, ADR). In this case the tension of a gear belt is correctly adjusted. If the top edge of the piston is in limits of the size B or With, it is necessary to make repeated adjustment of a tension of a gear belt, and also to check up a condition of a gear belt and a tension roller. If the top end face of the piston settles down in area In or the size D more than 29 mm, it is necessary to adjust position of a tension roller of a gear belt. If the top end face of the piston settles down in area With, it is necessary to adjust repeatedly position of a tension roller of a gear belt, and also to check up a condition of a gear belt together with a tension roller. If necessary establish a new gear belt and a tension roller.

Engine AHL

Use of a wrench for rotation of a tension roller of a gear belt on the clown on engine AHL

1 – an adjusting label, 2 – the index

PERFORMANCE ORDER

1. Engine AHL. Using a wrench or a special key, HAZET five times turn in both parties from an emphasis against the stop a tension roller of a gear belt on the clown, Use of a wrench for rotation of a tension roller of a gear belt fig. see the clown on engine AHL. 2. A wrench turn a tension roller counter-clockwise against the stop, thus the tension of a gear belt will be maximum. 3. Having released a wrench, ослабьте a tension of a gear belt also check up that the index was combined with an adjusting label (Use of a wrench for rotation of a tension roller of a gear belt fig. see the clown on engine AHL). In this position tighten a nut of fastening of a tension roller the moment of 20 Nanometers. 4. For a bolt of fastening of a pulley of a cranked shaft turn a cranked shaft of the engine clockwise on two complete revolutions and check up that all adjusting labels were combined with indexes. Check up that the adjusting label of the mechanism of a tension of a gear belt was combined with the index.

All engines

PERFORMANCE ORDER

1. Turn a cranked shaft of the engine on two complete revolutions clockwise and check up that all adjusting labels were combined with indexes. Otherwise remove a gear belt and make its repeated installation. 2. Establish the top casing of a gear belt. 3. Tighten a tension element поликлинового a belt the moment of 25 Nanometers. 4. Establish поликлиновой a belt.

Engine ADP

PERFORMANCE ORDER

1. Using the special equipment a Volkswagen, define the malfunctions which have been written down in memory, and erase memory contents. 2. Check up installation of a corner of an advancing of ignition.