3.5.2. Removal, installation and tension of a gear belt

Elements of the zubchatoremenny drive. The engine of 1.6 l is shown
1 – bolt, 45 N of m
2 – holder of the engine
3 – bolt, 25 N of m
4 – holder
5 – top cover of a gear belt
6 – average cover of a gear belt
7 – nut, 20 N of m
8 – washer
9 – tension roller
10 – gear belt
Check for wear. Before removal mark an arrow the direction of rotation. Do not bend a gear belt.
11 – back cover of a gear belt
12 – round sealing ring
Surely replace.
13 – pump of cooling liquid
14 – bolt, 15 N of m		 15 – cogwheel of a bent shaft
16 – bolt, 90 N. of m + 1/4 turns
Surely replace. The carving and a fillet should not have lubricants. Tighten a bolt 90 N.' moment of m and after that a rigid key tighten on 1/4 turns (90 °). Attention: Dovorachivaniye can execute in stages.
17 – lower cover of a gear belt
18 – bolt, 10 N of m
19 – power steering pump pulley
20 – maple belt
Before removal mark the direction of rotation.
21 – pulley of a cranked shaft / damper of tortional fluctuations
Installation is possible only in one situation. Openings are appropriately displaced.
22 – device of a tension of a maple belt.
For weakening of a maple belt incline a wrench.

Elements of the GRM zubchatoremenny drive. Petrol engine of 1.8 l / 125 h.p.
1 – bolt, 45 N of m
2 – engine support
3 – top cover of a gear belt
4 – bolt, 100 N of m
For an otvorachivaniye and an inhaling use the tool to deduction of Audi 3036
5 – camshaft pulley
Working situation: marking of VMT is visible.
6 – bolt, 45 N of m
7 – tension roller
8 – washer
9 – gear belt
Check for wear. Before removal mark the direction of rotation. Do not bend a belt.
10 – pump of cooling liquid
11 sealing ring
12 – bolt, 15 N of m
13 – device of a tension of a gear belt
14 – pulley of a gear belt of a bent shaft
Installation is possible only in one direction. Openings are displaced as appropriate.		 15 – bolt, 90 N of m + 1/4 turns. Surely replace. Oil a carving and a fillet. For an otvorachivaniye and an inhaling use the tool to deduction of Audi 3099. At installation of the tool for deduction between the tool and a pulley put two washers. Tighten a bolt the moment of 90 N of m and then tighten a rigid key on 1/4 turns (90 °). Attention: Dovorachivaniye can carry out in stages.
16 – average cover of a gear belt
17 – bolt, 10 N of m
18 – ridge maple belt
19 – pulley of a cranked shaft / damper of tortional fluctuations
Installation is possible only in one direction. Openings are displaced as appropriate.
20 – bolt, 25 N of m
21 – lower cover of a gear belt

Engines are equipped with automatically working tension roller in the drive of a gear belt supporting a belt tension always to constants. Thanks to it service life raises and the noise level of a gear belt decreases.

REMOVAL

PERFORMANCE ORDER
1. Take off maple a belt, at the same time address the subsection Removal and installation of a ridge maple belt.
2. Turn off a tension element of a maple belt.
3. Install the crankshaft in the provision of VMT of the end of a step of compression of the piston of the first cylinder, at the same time address the subsection Installation of the Piston of the first cylinder in VMT.
4. As the right support of the engine is disconnected, the engine needs to be suspended on AUDI-10-222A adaptation and 10-222A/1. Adaptation needs to be installed on fastening of a wing and will fix by hooks for engine eyes.
ATTENTION

If the specified adaptation is unavailable, it is necessary to bring the garage elevator with wooden laying under the pallet of a case and to slightly raise the engine.
5. Unscrew 4 screws with an internal hexagon and remove a pulley (a damper of tortional fluctuations) from a bent shaft. The engine at the same time keeps from a provorachivaniye for the central bolt.
6. Turn off bolts and uncover lower and top a gear belt.
7. Turn off bolts and remove a broad tank of cooling liquid and the tank of the hydraulic booster (are specified by shooters) and take aside with distributive lines.
8. Turn off bolts and disconnect the right support of the engine from a body and at the holder of the engine (are specified by shooters).
9. Turn off bolts and remove the right holder of the engine from the engine (are specified by shooters).
ATTENTION

For a detachment of a forward bolt it is necessary to raise a little the engine by means of adaptation.
10. Engines of 1.6 l: Turn off nuts of fastening of a tension roller of a gear belt.
Engine of 1.8 l
11. Screw a hairpin-1-M5x55 in the device of a tension of a gear belt.
12. Screw a nut –2– with a big washer –3– on a hairpin –1–.
It is necessary to pull a rod of the device of a tension until openings of a rod and the case coincide that will allow to insert a core with a diameter of 1.5 mm, a drill or the forelock (an arrow on an accompanying illustration). Now the rod is recorded, and the gear belt is unloaded.
All engines
13. Take off a gear belt.
ATTENTION

After removal of a gear belt do not change the provision of distributive and cranked shaft. If it is necessary to turn the camshaft at the taken-off gear belt, you watch that the bent shaft was not in VMT. Otherwise there is a danger of damage of valves and the bottom of the piston. For this purpose mark the provision of a pulley of a bent shaft, having applied with marking paint on a pulley of a bent shaft and the block of cylinders. Then turn forward or back a pulley of a bent shaft on 1/4 turns (90 °).

INSTALLATION

PERFORMANCE ORDER
1. At a tension of a gear belt the engine has to be cold.
2. Put on a gear belt cogwheels of a bent shaft and the pump of cooling liquid.
ATTENTION

If the old belt is established, surely observe the direction of its rotation. Installation of a belt in other situation can lead to its break and, as a result, to damage of the engine. Therefore surely establish gear belts so that the arrow put at removal of a belt specified in the direction of rotation of the engine. The engine, looking on the right side of the car, rotates in the direction of an hour hand.
3. Make sure that markings on wheels of cranked and distributive shaft coincide with the provision of marking of VMT. The engine is at the same time in the provision of VMT of the piston of the first cylinder.
4. Establish into place the lower cover of a gear belt and fix it.
5. Fix a pulley of a bent shaft by the moment of 25 N of m. Remark: The pulley is established only in one situation. Check that it was recorded.
6. Put on a gear belt a tension roller and a wheel of the camshaft.
Engine of 1.6 l
7. Check the provision of a tension roller: the clamp (an arrow on an accompanying illustration) has to enter a groove on a head of cylinders. Otherwise turn the holder.
8. Turn a tension roller for the clown the screw-driver, for example, of HAZET 2587 to the left (the direction of an arrow) so that a notch –1– and the index –2– stood opposite. For control it is possible to use a mirror if necessary. In this situation tighten a nut the moment of 20 N of m.
9. Turn the engine on 2 turns in the direction of rotation and again stop in the provision of VMT of marking of the camshaft. At the same time it is important that the last 45 ° were turned without stopping.
10. Check the provision of a notch –1– and the index –2–, they have to be opposite to each other. Otherwise it is necessary to establish a tension roller again.
Engine of 1.8 l
11. Take out a lock core (the shooter on an accompanying illustration) and turn out a carving pin –1–. The rod at a press element watches the correct tension of a gear belt.
All engines
12. Turn the engine twice and check the provision of VMT of distributive and cranked shaft. All markings at the tense gear belt have to coincide. Otherwise again take off a gear belt and repeat adjustment.
13. Establish the top cover of a gear belt.
14. Fix the right holder of the engine by the moment 45 N of m.
15. Fix the right support of the engine on a body and the holder of the engine by new bolts the moments presented in Specifications. At the same time at first tighten all bolts a dynamometer key, and then tighten a rigid key on a corner 90 ° (1/4 turns).
ATTENTION

Bolts at an inhaling receive a residual extract. Therefore after each inhaling it is necessary to apply new bolts.
16. Bolts at an inhaling receive a residual extract. Therefore after each inhaling it is necessary to apply new bolts.
17. Fix a tension element of a maple belt by the moment of 20 N of m.
18. Establish maple a belt, at the same time address the subsection Removal and installation of a ridge maple belt.
19. Fix a broad tank of the cooling system and the tank of liquid of the power steering.