Toothed Belt, with a Divided Toothed Belt Guard
Toothed Belt, with a Divided Toothed Belt Guard
• Vehicles from 01.06 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover => [ (Item 25) Cover for the Toothed Belt Guard ] Engine Overviews and the guard is divided in the engine mount bracket area. Toothed belt without a divided toothed belt guard removing and installing => [ Toothed Belt, without a Divided Toothed Belt Guard ] Toothed Belt, without a Divided Toothed Belt Guard.
Special tools, testers and auxiliary items required
• Engine Support Bracket (T10339)
• Insert Pad for Front Fender (T40045) , GTI only
• Adapter (10-222 A/18) , GTI and Eos only
• Bracket For Engine (10-222 A/1)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine Support Bridge (10-222 A)
Removing
- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.
Fuel system is under pressure!
• Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
• For safety reasons, interrupt the current supply to the fuel pump, refer to => [ Safety Precautions ] Safety Precautions before opening the fuel system because the fuel pump is activated by the driver door contact switch.
- Disconnect the lines - 1, 2 and 3 -. Press the release buttons.
GTI and Eos:
- Disconnect the ventilation line - 2 - and pull the Evaporative Emission (EVAP) canister - A - with hoses upward out of the bracket.
Continuation for all Vehicles:
Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.
- Open and close the coolant expansion tank cap to reduce the pressure.
- Loosen the clamp - arrow - and disconnect the coolant hose. Collect leaking coolant with a cloth.
- Disconnect the connector - 1 -. Loosen the coolant expansion tank bolts - arrows - and lay it on its side.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.
- Remove ribbed belt tensioner - A - and secure the bracket (T10339) to both upper threaded holes.
GTI:
- Install the engine support bridge (10-222 A) with the bracket for engine (10-222 A/1) and the adapter (10-222 A/18) on the fender edges.
- Install the insert pad for front fender (T40045) as shown under the right and left fender edges. Support the engine in installed position.
Eos:
- Install the engine support bridge (10-222 A) with the bracket for engine (10-222 A/1) and the adapter (10-222 A/18) on the fender edges. Support the engine in the installed position.
Passat:
- Remove the rubber stops - arrows - for the hood.
- Install the engine support bridge (10-222 A) with the bracket for engine (10-222 A/1) , as shown, on the fender edges. Support the engine in the installed position.
Continuation for all Vehicles:
Ensure that the fender edges are not damaged.
- Remove the upper toothed belt guard bolts - arrows -.
- Remove the noise insulation.
- Remove the right front part of the wheel housing liners.
- Remove the bolts - arrows - and disconnect the charge air pipe with hoses.
- Bring the camshaft sprocket to the mark for Top Dead Center (TDC) for cylinder 1 by rotating the crankshaft. The mark the on camshaft sprocket must align with the arrow on the toothed belt guard.
- Remove the vibration damper bolts.
• The TDC marks must align before removing the vibration damper.
• The crankshaft must not be rotated any more until the TDC position is marked with an assisting mark.
- Remove the lower toothed belt guard bolts - arrows - and guard.
- Identify the TDC position - arrow -.
- Remove the engine mount bracket bolt - 3 -.
- Loosen the bolts for the right wheel housing liner and push it aside.
- Remove the engine mount bracket bolt - 1 - through the hole in the wheel housing.
• The next step is necessary in order to be able to raise the engine far enough.
- Remove the pendulum support bolts - 2 and 3 -.
- Remove the engine mount to engine mount bracket bolts - arrows - and remove the engine mount completely.
Make sure that no components/hoses are damaged, overstretched or torn when lifting the engine using the engine support bridge (10-222 A).
- Lift the engine using the engine support bridge (10-222 A) until the upper engine mount bracket bolt - 2 - can be removed.
- Remove both toothed belt guard upper bolts - arrows - and remove the guard downward from the engine.
- Now, remove the engine bracket upward from the engine.
- Mark the rotational direction of the toothed belt, if reinstalling the old belt.
- Loosen the belt tension and remove the toothed belt.
- Then, turn the crankshaft back slightly.
Installing
• When turning the camshaft, the crankshaft must not be at TDC. The valves and/or pistons may be damaged.
• The engine must be no more than warm to touch.
• For the correct tightening specifications, refer to => [ Toothed Belt, with a Divided Toothed Belt Guard ] Engine Overviews.
- Position the camshaft and crankshaft to the TDC mark.
- Place the toothed belt onto the crankshaft toothed belt gear (observe the direction of rotation on a used belt).
- Route the toothed belt in the sequence: Belt tensioner, camshaft sprocket, coolant pump and lastly under the idler pulley - arrow -.
• Be sure the belt tensioner is properly seated in the cylinder head.
- Tension the toothed belt. To do so, turn the socket head wrench on the eccentric clockwise in the - direction of the arrow - until the notch aligns above the tab (toothed belt excessively tensioned).
- Release the tension on the toothed belt again.
- Now, tension the toothed belt until the notch and tab align.
- Tighten the toothed belt tensioner nut to 25 Nm.
- Rotate the crankshaft two additional turns in engine rotation direction until the engine again is at TDC. For this it is necessary that the last 45° (1/8) turn is done without interruption.
- Check the toothed belt tension. Specified value: The tab and notch align.
- Check the valve timing. The marks must align - arrows -.
If the marks do not match:
- Repeat the valve timing adjustment.
If the marks match:
- Bring the engine mount bracket into its installed position.
- Install the toothed belt guard from below and install the bolts - arrows -.
- Install the vibration damper using new bolts. Tightening specification: 20 Nm + 90° (1/4) additional turn.
- Check the valve timing again: The marks must align - arrows -.
- Tighten both toothed belt guard upper bolts - arrows -.
- Install the engine mount bracket to the cylinder block and tighten bolts hand tight.
• Note the different length of bolts. Bolt - 3 - is approximately 25 mm shorter than bolts - 1 and 2 -.
• Bolt - 1 - can be installed and tightened through the hole in the wheel housing.
- Lower the engine using the engine support bridge (10-222 A) until the lower bolt - 3 - can be tightened.
- Tighten all bolts to 45 Nm.
- Install the engine mount. For the correct tightening specifications, refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.
- Tighten the engine mount to engine bracket bolts - arrows - hand tight, by bringing the contact surfaces into contact using engine support bridge (10-222 A).
- Align the engine mount as follows:
• There must be a distance of at least 10 mm - a - present between the engine mount bracket - 2 - and right longitudinal member.
• The casting edge on the engine mount bracket - 2 - must be parallel to the engine mount - 1 -.
- Tighten the bolts for the engine mount to engine mount bracket. Tightening specification: => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.
- Remove the engine support bridge (10-222 A).
- Remove the bracket (T10339) and install the ribbed belt tensioner.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.
- Reconnect the fuel and ventilation lines. Make sure the connector couplings are securely fastened.
- Install the coolant expansion tank.
- Install the noise insulation.
- Restore the interrupted power supply.
- Install the engine cover/upper air filter housing.