Toothed Belt, With Divided Toothed Belt Guard
Toothed Belt, with Divided Toothed Belt Guard
• Vehicles from 01.06 have a new toothed belt guard. Distinguishing feature: the upper toothed belt guard does not have a cover - item 25 -=> [ Toothed Belt Guard Cover ] Engine Overview and the guard is divided in the engine mount bracket area. Toothed belt, without divided toothed belt guard, removing and installing. Refer to => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, Without 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 - 222A/18), GTI and Eos only
• Bracket for Engine (10 - 222A/1)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine Support Bridge (10 - 222A)
Removing
- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.
CAUTION!
The fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before disconnecting the connections, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.
• 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 fuel and ventilation lines - 1, 2 and 3 -. To do so, press the release buttons.
- Disconnect the ventilation hoses - 1 and 2 - and pull the Evaporative Emission (EVAP) canister - A - with the hoses upward out of the bracket.
CAUTION!
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 any leaking coolant with a cloth.
- Disconnect the connector - 1 - from the expansion tank. Loosen the bolts and lay it on its side.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the ribbed belt tensioner - A - and install the (T10339) using both upper threaded holes.
GTI
- Install the (10 - 222 A) using (10 - 222 A/1) and (10 - 222 A/18) on the fender edges.
- Install the (T40045) as shown under the right and left fender edges. Support the engine in the installed position.
Eos
- Install the (10-222A) using (10-222A/1 ) and (10 - 222A/18) on the fender edges. Support the engine in the installed position.
Passat
- Remove the rubber stops - arrows - for the hood.
- Install the (10-222A) using (10-222A/1 ), as shown, on the fender edges. Support the engine in the installed position.
Continuation for All
CAUTION!
Ensure that the fender edges are not damaged.
- Remove the upper toothed belt guard bolts - arrows - and remove the upper toothed belt guard.
- Remove the noise insulation.
- Remove the front part of the right wheel housing liner.
- Remove the charge air pipe bolts - arrows - and disconnect the charge air pipe with hoses.
- Bring the camshaft gear mark to Top Dead Center (TDC) for cylinder 1 by turning the crankshaft. The mark on the camshaft gear must align with the arrow on the toothed belt guard.
- Remove the vibration damper.
• The TDC marks must align before removing the vibration damper.
• The crankshaft must not be rotated any more until TDC position is marked with an assisting mark.
- Remove the lower toothed belt guard bolts - arrows -.
- Identify the TDC position - arrow -.
- Remove the lower engine mount bracket bolt - 3 -.
- Loosen the right wheel housing liner bolts and push it aside.
- Remove the engine mount bracket - 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.
CAUTION!
Make sure that no components/hoses are damaged, overstretched or torn when lifting the engine using (10-222A).
- Lift the engine using (10-222A) until the upper bolt - 2 - for the engine mount bracket can be loosened and removed.
- Remove both upper toothed belt guard bolts - arrows - and remove the guard downward from the engine.
- Remove the engine mount bracket upward from the engine.
- If reinstalling the toothed belt, mark the rotational direction of the toothed belt.
- Loosen the semi automatic tensioning roller nut and remove the toothed belt.
- Then, turn the crankshaft back slightly.
Installing
• When turning the camshaft, the crankshaft must not be at TDC. Valves and/or pistons may be damaged.
• The engine must be no more than warm to touch.
• Tightening specifications, refer to => [ Toothed Belt Overview, With Divided Toothed Belt Guard ] Engine Overview.
- Position the camshaft and crankshaft on the TDC marks.
- Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).
- Route the toothed belt in the following sequence: semi automatic tensioning roller, camshaft gear, coolant pump, and finally around the idler roller - arrow -.
• Be sure the semi automatic tensioning roller is properly seated in the cylinder head.
- Tension the toothed belt. To do so, install the wrench on the eccentric and turn it 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.
- Tension the toothed belt until the notch and tab align.
- Tighten the semi automatic tensioning roller nut to 25 Nm.
- Rotate the crankshaft two additional turns in engine rotation direction until the engine is again at TDC. For this it is necessary that the last 45° (1/8) rotation is turned without interruption.
- Check the toothed belt tension. Target value: tab and notch are positioned across from each other.
- Check the valve timing. The marks - arrows - must align.
If the marks do not match:
- Repeat the valve timing adjustment.
If the marks match:
- Bring the engine mount bracket into the installed position.
- Install the toothed belt guard and bolts - arrows - from below.
- Install the vibration damper with new bolts. Tightening specification: 20 Nm + 90° (1/4) additional turn.
- Check the valve timing again: the marks - arrows - must be aligned.
- Tighten both lower toothed belt guard upper bolts - arrows -.
- Install the engine mount bracket to the cylinder block and tighten the 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 through the hole in the wheel housing and tightened.
- Lower the engine using (10-222A) until the lower bolt - 3 - can be tightened.
- Tighten all bolts to 45 Nm.
- Install the engine mount. 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 (10 - 222A).
- 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 engine mount and engine mount bracket bolts. Tightening specifications, refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.
- Remove the (10 - 222 A).
- Remove the (T10339) and install the ribbed belt tensioner.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Connect the fuel and ventilation lines. Make sure the connector couplings are securely fastened.
- Install the coolant expansion tank.
- Install the noise insulation.
- Restore the power supply.
- Install the engine cover/upper air filter housing.