Note: Replace screws that are tightened by turning the specified angle. If the sealing ring of the threaded plug is damaged, replace the sealing ring.
Check the "TDC" position of the camshaft and crankshaft. The "T10494" camshaft lock is installed on the camshaft housing.
Caution! Risk of damage to camshafts. Do not use the "T10494" camshaft locking tool as a stop.
The locking bolt "T10340" is screwed into the cylinder block until it stops and tightened to a torque of 30 Nm. The crankshaft is turned forward until it touches the locking screw "T10340" = the "TDC" position. Screw in new screws -1, 2- of the camshaft pulleys by hand. The camshaft pulleys should still turn on the camshafts, but should not wobble.
The projection of the tension roller "arrow" must enter the cast recess of the cylinder head.
Install the toothed crankshaft pulley on the crankshaft. The mating surfaces between the poly V-belt pulley and the toothed crankshaft pulley must be free of grease. The milled flat part of the "arrow" of the toothed crankshaft pulley must fit onto the milled chamfer on the nose of the crankshaft.
When installing/reeving the toothed belt, observe the correct sequence. Lift the toothed belt up and install it on the guide roller "1" and tension roller "2", and then on the camshaft pulleys "3" and "4".
Turn the eccentric "2" of the tension roller with the "TW499" key in the "direction of the arrow" so that the arrow "3" goes approximately 10 mm to the right beyond the notch. Turn the eccentric back so that the arrow is exactly opposite the notch.
Caution! Use the torque wrench "VAS 6583" for tightening! When setting the tightening torque on the torque wrench "VAS 6583", it is necessary to enter the length parameter specified on the nozzle "T10500"!
While holding the eccentric in this position, tighten bolt "1" to a torque of 25 Nm, using the "T10500" attachment with the "VAS 6583" torque wrench.
Note: Later, after turning the crankshaft or starting the engine, there may be slight deviations of the arrow "3" from the position opposite the notch. This is normal and does not have a negative effect on the tension of the toothed belt.
Tighten screws -1, 2- to a preliminary torque of 50 Nm; using the stopper "T10172" with adapters "T10172/2" and "T10172/1".
Unscrew the lock bolt "T10340". Unscrew the screw "arrow" and remove the camshaft lock "T10494". Install the lower protective cover of the belt "arrow". Install the crankshaft pulley.
Checking the installation of the timing phases
Turn the crankshaft 2 turns in the direction of engine rotation. Screw the locking bolt "T10340" into the cylinder block until it stops and tighten to a torque of 30 Nm. Turn the crankshaft further in the direction of engine rotation until it stops. The crankshaft counterweight is now adjacent to the locking bolt.
Note: The locking bolt "T10340" locks the crankshaft only in the working direction of rotation. The camshaft lock "T10494" must be easy to insert. The camshaft lock must not be installed with an impact tool.
Insert the "T10494" locking tool into the camshafts until it stops and tighten the "arrow" screw by hand. If the "T10494" camshaft locking tool does not fit, the valve timing is not correct: repeat the valve timing adjustment. If the "T10494" camshaft locking tool fits, the valve timing is correct. Unscrew the "T10340" locking bolt. Unscrew the "arrow" screw and remove the "T10494" camshaft locking tool. Tighten bolts -1, 2- to the final tightening torque, using the "T10172" stop with the "T10172/2" and "T10172/1" adapters.
Tighten the threaded plug "1" to a torque of 20 Nm, using the stop "T10172" with the adapter -110172/1-.
Caution. Risk of engine damage. After completing the work, be sure to ensure that the locking bolt "T10340" and the camshaft lock "T10494" are not left on the engine.
Installation in reverse order.