Volkswagen Workshop Service and Repair Manuals

Removing

–  Remove cover above camshaft housing -arrows-. –  Remove air filter → Fig.. –  Remove upper toothed belt guard.

–  Position crankshaft at TDC No. 1 cylinder. The notch on pulley must align with edge of -O- mark.

–  The locking pin holes in the camshaft pulleys must align with the fitting holes in the camshaft housing -arrows-.   Note If the locking pin holes are positioned to the outside on the toothed belt pulleys, the crankshaft must be turned one revolution further. Lock both camshaft sprockets with camshaft lock -T10016- as follows:

–  Guide both positioning pins through camshaft pulley locking pin holes as far as stop in camshaft housing fitting holes.   Note Both positioning pins are inserted correctly when the ends -D- align with line -A-. –  Slide retainer -B- to stop against inlet camshaft pulley -C-. The engine must be lowered slightly as follows to enable the crankshaft pulley to be removed:

–  Fit support bracket -10 - 222 A- with frame -10 - 222 A /1- as shown. –  Remove power-assisted steering reservoir and lay to side. –  Remove upper securing bolt from lower toothed belt guard beneath engine bracket. –  Take up weight of engine and remove right engine bracket as shown.

–  Completely remove securing bolts -B- and assembly mounting. –  Remove engine bracket on cylinder head. –  Remove right noise insulation. –  Lower engine until the pulley securing bolt is accessible. –  Mark the direction of rotation of poly V-belt and remove belt as follows:

–  Pivot tensioning roller in direction of arrow by turning securing bolt with straight ring spanner. –  Remove poly V-belt.

–  Remove pulley securing bolt and toothed belt pulley. Fix belt pulley with counterhold -3415- and pin -3415/1- (on ATN, AUS, AZD, BCB with counterhold -T10028-). –  Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt pulley. –  In case of vehicles with air conditioning system remove idler roller and tensioning roller for poly V-belt. –  Remove lower toothed belt guard. –  Mark direction of rotation of both toothed belts. Remove main drive toothed belt

–  Release main drive tensioner -1- and slacken toothed belt by turning tensioning roller anti-clockwise -arrow-. –  Loosen clamping bolt on tensioning roller. –  Remove toothed belt. Removing coupling drive toothed belt:

–  Loosen coupling drive tensioner -1- and slacken toothed belt by turning tensioning roller clockwise. –  Remove coupling drive tensioning roller. –  Remove toothed belt.