Toothed Belt, Without Divided Toothed Belt Guard

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

• In order to be able to remove the engine mount bracket, the engine must be lifted quite far using (10-222A). To prevent damage to the drive axles from significant bend angles, 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.

CAUTION!
The fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before disconnecting the line connections, place a cloth around the connection point. Then release pressure by carefully disconnecting 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 fuel and ventilation lines - 1, 2 and 3 -. To do so, press the release buttons.

GTI and Eos





- Disconnect the ventilation hoses - 1 and 2 -. Remove the Evaporative Emission (EVAP) canister - A - with the hoses upward from the bracket.

Continuation for All

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 tank bolts - arrows - and lay it on its side.





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

- Remove the belt tensioner - A - and install the (T10339) using both upper threaded holes.





GTI





- Install the (10-222A) using (10-222A/1 ) and (10 - 222A/18) on the fender edges.

- Install the (T40045) as shown under the right and left fender edge. 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 edge. Support the engine in the installed position.





Continuation for All

CAUTION!
Ensure that the fender edges are not damaged.

- Remove the noise insulation.

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





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





- Remove the vibration damper bolt.





- 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 exhaust pipe with catalytic converter to turbocharger nuts - arrows -.





- Remove the 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) pipe clamp - arrows - bolts from the body.





• 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.





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) far enough until the upper bolt - 2 - for the engine mount bracket can be loosened and 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.





- 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, Without Divided Toothed Belt Guard ] Engine Overview.

- Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).

- Install the lower toothed belt guard with the two lower bolts.

- Install the vibration damper with 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 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 at TDC again. For this, it is necessary that the last 45° (1/8) rotation is turned without interruption.

- Check the tension of the toothed belt again. Target value: the tab and notch are positioned across from each other.

- 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 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 - 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 with the engine mount - 1 -.

- Tighten the bolts for the engine mount and engine mount bracket. Tightening specifications, refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.

- Remove the (10 - 222 A).

- Remove the (T10339) and install the belt tensioner.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- 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 power supply.

- Install the engine cover/upper air filter housing.