Removal and Replacement

Toothed belt, removing, installing and tensioning





Special tools, testers and auxiliary items required
^ Engine support bridge 10-222A (modify Adapter 10-222A/21)
^ Engine support feet 10-222A/8
^ Torque wrench V.A.G1331
^ Torque wrench V.A.G1332
^ Toothed belt tensioner T10020

Modifying Adapter 10-222A/21 of the Engine support bridge 10-222A

To support the engine/transmission assembly, the Engine support bridge 10-222A is necessary.





To secure the Engine support feet 10-222A/8 to the Adapter 10-222A/21, it will be necessary to drill a new hole.

Measurements in mm.
- Drill a 12.5 mm diameter hole - arrow - into Adapter 10-222A/21 at location shown in illustration.

Removing
- Remove right side sound insulation.
- Remove engine cover.
- Remove poly V-belt.
- Remove tensioner for poly V-belt.
- Remove coolant expansion tank (coolant hoses remain connected).
- Remove toothed belt guard - upper part.





- Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft pulley must align with arrow on toothed belt guard - arrows -.





- Fit Engine support bridge 10-222A with Engine support feet 10-222A/8 as shown.





- Remove assembly mounting - 1 - as follows:





- Remove bolts - arrows-.
- Loosen bolt - arrow A -.

Note:
^ The assembly mounting may only be removed if the engine is supported with engine support bridge 10-222A!
^ The engine mounting may only be loosened if the assembly mounting has been removed.

- Remove vibration damper/belt pulley.
- Remove bolts - arrows - and remove engine bracket from cylinder head.

Note:
The engine must be lifted slightly with the support bridge when loosening the front bolt of the engine bracket.

- Remove middle and lower toothed belt guard.
- Mark direction of rotation of toothed belt.
- Loosen tensioning roller and take toothed belt off.
- Turn crankshaft back slightly.

Installing

Condition
^ Pistons must not be positioned at TDC. Turn crankshaft back slightly if necessary.

Work sequence
- Place toothed belt on crankshaft pulley and coolant pump pulley (observe marked direction of rotation).

Note:
^ With engine removed, begin by installing the lower toothed belt guard and the damper/belt pulley.

Adjusting valve timing

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





- Align mark on camshaft with mark on toothed belt cover - arrows -.

Engine installed





- Turn crankshaft to TDC No.1 cylinder (vehicles with a manual transmission).





- Turn crankshaft to TDC No.1 cylinder (vehicles with an automatic transmission).

Engine removed





- Position vibration damper at TDC No. 1 cylinder - arrows -.

Continued for engine removed or installed
- Install toothed belt on tensioning roller and camshaft pulley.

Tensioning toothed belt

Requirements
^ Engine must be no more than warm to touch.
^ Camshaft positioned at TDC for cylinder 1.
^ Before tensioning toothed belt, turn tensioning roller 5 times to limit stop (in both directions) at eccentric using toothed belt tensioner T10020.

Work sequence





- Turn eccentric to left (direction of arrow) onto limit stop using toothed belt tensioner T10020.
- Relieve tension on toothed belt until notch - 1 - and indicator - 2 - are aligned (use mirror).
- Tighten securing nut to 20 Nm.
- Turn crankshaft two rotations in engine direction of rotation until engine is on TDC No. 1 cylinder again. When doing this it is important that last 45° (1/8 turn) is completed without interruption.
- Check tension of toothed belt again.
- Specification: indicator and notch align

Continuation for completing installation of toothed belt
- Install middle and lower toothed belt guard.
- Install vibration damper/belt pulley.
- Tightening torque: 25 Nm
- Install engine bracket to cylinder block.
- Tightening torque: 45 Nm

Note:
^ Insert the engine bracket bolts into the bracket before installing it.
^ Before installing the assembly mounting, all engine mounting bolts must be tightened to the prescribed torque.

- Install engine assembly mounting complete.
- Align engine and transmission mountings.
- Prescribed tightening torques for assembly mounting: Assembly mountings
- Remove Engine support bridge 10-222A.
- Install toothed belt guard upper part.
- Install poly V-belt tensioner.
- Tightening torque: 25 Nm
- Install Poly V-belt.
- Install coolant expansion tank.
- Install right side sound insulation.
- Install engine cover.