Removal and Replacement

Toothed belt, removing, installing and tensioning





Special tools, testers and auxiliary items required
^ Engine support bridge 10-222 A with adapter 10-222 A-8
^ Retainer 3180
^ Tensioning bolt T10092
^ Pin T40011
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Locking fluid D 000 600 A2

Removing
- Remove engine cover.
- Remove right sound insulation.





- Remove air duct pipe to charge air cooler on longitudinal member, lower right.
- Remove ribbed belt.
- Remove tensioning element for ribbed belt.
- Set crankshaft to TDC No. 1 cylinder:





^ When engine is installed (vehicles with manual transmission)





^ When engine is installed (vehicles with automatic transmission)





^ When engine is removed, turn vibration damper to TDC No. 1 cylinder - arrows -.
- Remove coolant expansion tank and place to side.
- Pull off vacuum line to throttle valve support.
- Remove toothed belt guard upper part.





- Position engine support bridge 10-222 A with legs 10-222 A-8.
- Hook retainer 3180 on right lifting eye and put engine under slight tension.





- Remove securing bolts from assembly mounting-engine bracket, assembly mounting-body and assembly mounting bracket - body - arrows - and remove assembly mounting complete.





- Remove vibration damper-belt pulley.
- Remove lower and middle toothed belt guards.





- Remove engine bracket from cylinder head.

Note:
^ The engine must be lifted slightly or lowered with the support bridge when loosening the bolts of the engine bracket.
- Mark direction of rotation of toothed belt.





- Install tensioning bolt T10092 in tensioning element for ribbed belt.
- Before tensioning, align pressure piston with long nose pliers or a thin wire, if necessary (pressure piston hole and housing hole must align).
- Tension pressure piston of tensioning element until pressure piston can be secured with pin T40011. Remove toothed belt.
- Turn crankshaft back slightly.

Installing

Note:
^ When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves-piston crown.

A - Toothed belt removed completely

The toothed belt was removed only from the camshaft pulley

Requirement
^ Pistons must not be positioned at TDC.

Work sequence





- Align mark on camshaft pulley with mark on cylinder head cover.
- Place toothed belt on crankshaft pulley (observe direction of rotation).
- Install engine bracket to cylinder block.
- Tightening torque: 45 Nm

Note:
^ Before installing, insert bolts into engine bracket.

- Install toothed belt guard lower part (insert securing bolts with locking fluid D 000 600 A2).
- Tightening torque: 10 Nm
- Install vibration damper-belt pulley with a bolt.





- Set crankshaft to TDC No. 1 cylinder.
- Place toothed belt on coolant pump, tensioning roller and camshaft pulley.
- Tension toothed belt

B - Toothed belt removed from camshaft pulley only





- Align mark on camshaft pulley with mark on cylinder head cover.
- Set crankshaft to TDC No. 1 cylinder.
- Place toothed belt onto camshaft pulley.
- Tension toothed belt

Tensioning toothed belt





- Pull pin T40011 out and remove tensioning bolt T10092.
- Turn crankshaft two full turn in direction of engine rotation and check whether camshaft and crankshaft markings align with their reference points.
- Install vibration damper-belt pulley
- Tightening torque: 25 Nm
- Install toothed belt guard center part (insert securing bolts with locking fluid D 000 600 A2).
- Tightening torque: 10 Nm
- Install toothed belt guard upper part.
- Install assembly mounting and engine bracket (tightening torques Assembly mountings, tightening torques
- Install ribbed belt tensioning element.
- Tightening torque: 25 Nm
- Install ribbed belt.
- Install air duct pipe to charge air cooler on longitudinal member lower right.
- Installing right sound insulation.