VIDEO PART 3 - Install new Camshaft toothed belt with new tension roller and new Coolant pump on VW T4 ACV 2.5TDI 75KW

Removing and installing Toothed belt

• Remove vibration damper centre bolt. (torque 160 Nm and turn 180° (1/2 turn))
• Loosen the 4 x M8 crankshaft vibration damper/toothed belt pulley securing bolts and remove 2 opposing bolts. (torque 20 Nm and turn 90° (1/4 turn))
• Loosen the 2 remaining bolts until the vibration damper can be released from crankshaft toothed belt pulley by a light hammer blow on the bolt heads.
• Remove vibration damper.
• Remove lower toothed belt guard.
• Mark D.O.R. of toothed belt.
• Relieve toothed belt tension with ring spanner 3355.
• Take off toothed belt.

Installing, tensioning

• Remove injection pump drive sprocket.
• Check whether TDC mark on flywheel and reference mark are aligned.
• Lock camshaft with setting bar 2065 A.

• Loosen camshaft sprocket securing bolt a 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).
  

• Install tensioning roller -1- so that the retaining lug locates on the retaining pin -2- on the lower part of the toothed belt guard.
• Fit toothed belt for camshaft drive. For used belts note direction of rotation.
• Tighten tensioning roller securing bolt hand tight.

• To tension the toothed belt turn the tensioning roller clockwise with ring spanner 3355 -direction of arrow-, until the right edge of indicator -A- aligns with right edge of indicator -B-.
• Note:
  The right edge of indicator -A- must not be rotated past the right edge of indicator -B-, otherwise the tensioning roller can be damaged.
  If it does happen that it is turned too far, the tensioning roller must be fully released and then retensioned. You must not turn the eccentric back by purely the amount it has been turned too far.
• Tighten tensioning roller securing bolt to 20 Nm.

• Check if crankshaft is still on TDC No. 1 cylinder, correct if necessary.
• Tighten camshaft sprocket securing bolt using counter-hold 3036.
  Observe steel type marking on bolt head:
  8.8 = 85 Nm
  10.9 = 100 Nm
• Remove setting bar 2065A from camshaft

• Install lower toothed belt guard.
• Fit vibration damper with new centre bolt.
• Insert counter-hold T10025 and tighten vibration damper/crankshaft toothed belt sprocket centre bolt to 160 Nm and turn 180° (1/2 turn) further (turning further can be completed in several stages).

• Tighten the 4 x M8 crankshaft vibration damper/toothed belt pulley securing bolts to 20 Nm and turn 90° (1/4 turn) further (turning further can be completed in several stages).
• Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
• Again check the position of the tensioning roller indicator. If the right edges of indicator -A- and -B- do not align, the tensioning procedure must be repeated.

Description

1. Toothed belt guard - upper part
2. Camshaft toothed belt (Mark Direction D.O.R. before removing, Check for wear, Do not kink
3. Camshaft sprocket securing bolt (Observe steel type marking on bolt head: 8.8 = 85 Nm, 10.9 = 100 Nm, Counter-hold with 3036 to loosen and tighten)
4. Camshaft sprocket - (Drive off camshaft taper using hammer and drift through toothed belt guard openings, Note position when installing toothed belt)
5. Toothed belt guard - rear
6. 20 Nm
7. Coolant pump
8. O-ring (If leaking and damaged renew)
9. Toothed belt guard - lower part
10. 10 Nm
11. Tensioning roller
12. Crankshaft toothed belt sprocket
13. Toothed belt guard