Toothed Belt, without a Divided Toothed Belt Guard

Toothed Belt, without 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, with a divided toothed belt guard removing and installing. Refer to => [ Toothed Belt, with a Divided Toothed Belt Guard ] Toothed Belt, with 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)

• In order to be able to remove the engine mount bracket, the engine must be lifted quite far using the engine support bridge (10-222 A). To prevent damage to the drive axles from bending significantly, it is necessary to disengage the drive axles from the transmission.

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:






- Remove the breather line - 2 -. Remove the Evaporative Emission (EVAP) canister - A - with hoses upward from 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 in order to reduce the pressure.

- Loosen the clamp - arrow - and disconnect the coolant hose. Collect leaking coolant with a cloth.






- Disconnect the connector - 1 -. Remove the coolant expansion tank bolts - arrows - and lay it on its side.






- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.

- Remove the ribbed belt tensioner - A - and install the engine support bracket (T10339) to both 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 on the right and left fender edges. Support the engine in the 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 noise insulation.

- Remove the right front part of the wheel housing liners.






- Set the camshaft sprocket to the mark for Top Dead Center (TDC) by rotating the crankshaft. The mark on the camshaft sprocket must align with the arrow on the toothed belt guard.






- Remove the vibration damper bolts.






- Remove the lower toothed belt guard bolts - arrows -.






- Remove the lower 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 steps are necessary in order to be able to lift the engine far enough.

- Remove the front exhaust pipe to turbocharger nuts - arrows -.






- Remove the front exhaust pipe with catalytic converter from the turbocharger.

- Remove the pendulum support bolts - 2 and 3 -.






- Remove the drive axles from the transmission.

- Remove the Air Conditioning (A/C) system pipes from the body - arrows -.






• The A/C system does not need to be opened!

- 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 the lifting engine using the engine support bridge (10-222 A).

- Lift the engine using the engine support bridge (10-222 A) far enough until the upper engine mount bracket bolt - 2 - can be removed.






- Continue to raise the engine until the engine mount bracket can be removed upward.

- Remove the remaining toothed belt guard bolts - arrows - and remove the toothed belt guard from the engine.






- Mark the rotational direction of the toothed belt, if reinstalling the old belt.

- Loosen the belt tensioner and remove the 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, without a Divided Toothed Belt Guard ] Engine Overviews.

- Place the toothed belt onto the crankshaft toothed belt gear (observe the direction of rotation if reinstalling the old belt).

- Secure the lower toothed belt guard to the block using the two lower bolts.

- Install the vibration damper using new bolts. Tightening specification: 20 Nm + 90° (1/4) additional turn.

- Set the crankshaft and camshaft to TDC for cylinder 1 - arrows -.






- Route the toothed belt in this 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 is 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 belt tensioner nut to 25 Nm.

- Rotate the crankshaft two additional turns in the engine rotation direction until the engine is again at TDC. For this it is necessary that the last 45° (1/8 turn) is turned without interruption.

- Check the tension of the toothed belt again. Specified value: The tab and notch align.

- Check the valve timing again.






If the marks do not match:

- Repeat the valve timing adjustment.

If the marks match:

- Install the toothed belt guard bolts - arrows -.






- Install the engine mount bracket to the cylinder block from above and tighten the bolts hand tight.

• Note the different length of the 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 the 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 mount bracket bolts - arrows - hand-tight, by bringing the contact surfaces into contact using the 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 the 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 and engine mount bracket. Tightening specification, refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.

- Remove the engine support bridge (10-222 A).

- Remove the engine support 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 and check the coolant level.

- Install the noise insulation.

- Restore the interrupted power supply.

- Install the engine cover/upper air filter housing.