Auto Manual of VW Passat B5

2.5.1. Removal and installation of a gear belt

THE GENERAL DATA

Mechanism drive timing the diesel engine

1 – a fixing clip; 2 – the top casing of a gear belt; 3 – a gear belt. Before removal of a gear belt it is necessary to put on it an arrow specifying a direction of a gear belt; 4 – a nut, 20 Nanometers; 5 – the clown; 6 – a tension roller of a gear belt; 7 – a bolt, 45 Nanometers; 8 – a camshaft pulley; 9 – a bolt, 25 Nanometers; 10 – a directing roller; 11 – a bolt, 10 Nanometers; 12 – a back casing of a gear belt; 13 – fuel насо; 14 – an arm;

15 – the console; 16 – a pulley of the fuel pump; 17 – a nut, 55 Nanometers; 18 – a pulley of the fuel pump from two sections; 19 – a pulley of an intermediate shaft; 20 – a pulley of a gear belt of a cranked shaft; 21 – a bolt of fastening of a pulley of a cranked shaft, 90 Nanometers to tighten on a corner 90 ; 22 – bolts for fastening of a compound pulley of the fuel pump of a high pressure, 20 Nanometers to tighten on a corner 90 . At installation it is necessary to use new bolts; 23 – the bottom casing of a gear belt; 24 – гаситель fluctuations/pulleys auxiliary приводного a belt. Pulley installation is possible only in one position after combination of apertures.

All operations on removal and installation of a gear belt on the diesel engine are similar to operations on removal and installation of a gear belt on four-cylinder petrol engines. Further in this subsection operations which are characteristic only for engines 1,9-I-TDI are stated.

The adaptation necessary for fixing of a camshaft of diesel engines

PERFORMANCE ORDER

1. Using a wrench, turn a tension roller поликлинового a belt against the stop counter-clockwise and in this position of a roller remove the top casing of a gear belt. 2. Turn a cranked shaft of the engine in position of installation of the piston of the first cylinder in the top dead point. 3. For blocking of a camshaft and a pulley of the fuel pump of a high pressure in position ВМТ of the piston of the first cylinder in a compression step it is necessary to use special blocking tools, fig. the Adaptation necessary for fixing of a camshaft of diesel engines see. 4. Establish the tool for blocking in a groove in a camshaft end face. 5. With the tool of blocking established in a camshaft, turn a camshaft (turning a cranked shaft clockwise) so that the tool of blocking by one party has nestled on a surface of a head of the block of cylinders. Using an edge щупа, measure a backlash between the second end of the tool of blocking and a head of the block of cylinders. Turn a camshaft slightly back and from two parties between the tool of blocking and a head of the block of cylinders establish two щупа in the thickness equal to half before the measured backlash. 6. Through an aperture in картере couplings check up that label ВМТ on a flywheel is combined with the index.

Engines with a monoblock pulley of the fuel pump

PERFORMANCE ORDER

1. Insert a blocking pin through an adjusting aperture of a pulley of the fuel pump of a high pressure into an aperture in an arm behind a pulley of the fuel pump. 2. The blocking pin can be made independently according to the sizes on fig. the Adaptation necessary for fixing of a camshaft of diesel engines.

Engines with a two-section pulley of the fuel pump

PERFORMANCE ORDER

1. Block a pulley of the fuel pump a fixing pin. 2. From a pulley of the fuel pump unscrew bolts (1) and on their place screw in new bolts, having tightened their moment of 20 Nanometers. Do not unscrew those the central nut of fastening of a pulley of the fuel pump as thus the pulley can be displaced. 3. Ослабьте a tension of a gear belt, having unscrewed a nut of fastening of a pulley of the mechanism of a tension. 4. Unscrew a bolt and remove directing roller of a gear belt. For repeated installation of a gear belt note a direction of its rotation. 5. Ослабьте a bolt of fastening of a pulley of a camshaft on half of turn. Remove a pulley of a gear belt of a camshaft from an adjusting cone of a camshaft, using выколотку, passed through an aperture in a back casing of a gear belt. 6. Establish directing roller of a gear belt and fix its bolt, having tightened its moment of 25 Nanometers. 7. Establish a gear belt on a pulley of a cranked shaft, a pulley of the fuel pump and a camshaft pulley. 8. Establish a gear belt the flat party on a pulley of an intermediate shaft and a roller of the mechanism of a tension. 9. Remove a pin of blocking of the fuel pump of a high pressure. 10. Check up that the forward part of a gear belt is hardly tense, and belt sagging should be from outside a roller of the mechanism of a tension. 11. Using a wrench, turn the mechanism of a tension of a gear belt clockwise before combination of labels on a pulley and a nave of the mechanism of a tension. 12. Check up a tension of a gear belt, turning it in the centre between intermediate and a camshaft. Thus the belt should turn only on 90 . 13. After carrying out of adjustment of a tension of a gear belt tighten a counternut of the mechanism of a tension the moment of 45 Nanometers. 14. Tighten a bolt of fastening of a pulley of a camshaft the demanded moment. 15. Remove the tool of blocking of a camshaft. 16. Turn a cranked shaft of the engine on two complete revolutions in a normal direction of rotation and repeatedly establish the piston of the first cylinder in ВМТ in a compression step. Check up that the pin блокирова ния can be established in установоч ное an aperture of a pulley of the fuel pump of a high pressure. Check up and, if necessary, repeatedly adjust a tension of a gear belt. 17. Establish casings of a gear belt, гаситель fluctuations/pulleys вспомогательно го приводного a belt and a cover of a head of the block of cylinders. 18. Establish поликлиновой an auxiliary belt. 19. Check up installation of the moment of injection of the fuel pump of a high pressure. The prevention On the gear wheel of the fuel pump consisting of two sections after installation of the moment of injection of the fuel pump tighten three bolts of fastening of a gear wheel the moment of 20 Nanometers, and then tighten them on a corner 90 .