Volkswagen Workshop Service and Repair Manuals

Removing –  Remove engine cover. –  Remove upper toothed belt guard.

–  Fit support bracket -10 - 222 A- as shown and take up weight of engine in installation position. –  Unbolt cooling system expansion tank and lay to side. –  Unbolt power-assisted steering reservoir and place to side. –  Take up weight of engine and remove right engine bracket as shown.

–  Unscrew securing bolts from assembly mounting/engine bracket, assembly mounting/body and assembly mounting/body bracket -arrows- and remove assembly mounting complete.

–  Remove upper securing bolt -1- from lower toothed belt guard -2- under engine mounting -3-. –  Remove coolant hose from engine bracket -3-. –  Remove engine bracket -3-. –  Raise vehicle. –  Remove right wheel housing liner: → General body repairs, exterior; Rep. gr.66

–  Turn crankshaft in engine direction of rotation until both fixing holes of camshaft adjuster and exhaust camshaft pulley align with fitting holes in camshaft housing -arrows-. –  Lock camshaft adjuster and exhaust camshaft pulley using locking pin -T10074- as follows:

–  First fit retaining plate -T10073- on camshaft adjuster.

–  Push locking pin -A- into fitting hole in camshaft adjuster and camshaft housing onto stop. –  Then lock exhaust camshaft pulley by pushing a locking pin -B- through second hole in retaining plate -T10073- in fitting hole of camshaft housing to stop.   Note The locking process is made easier by turning exhaust camshaft pulley slightly on securing bolt with a ring spanner until the fitting holes align. –  Unscrew camshaft adjuster plug. –  Collect leaking engine oil. –  Close opening in cover with clean cloths. –  Remove locking pins -T10074- and retaining plate -T10073-.   WARNING The cover of the camshaft adjuster is under tension from a strong spring. It is essential to secure the cover as follows to prevent accidents.

–  Remove two opposing securing bolts -3- for the cover. –  Screw the studs -2- into these holes until they are flush with the rear of the camshaft pulley. –  Screw a nut onto each stud -2- until it just contacts the cover. –  Remove the remaining securing bolts -3- for the cover. –  Then evenly unscrew the nuts on the studs -2-.   Note Ensure the studs -2- do not unscrew from the camshaft pulley. –  Collect leaking engine oil.

–  Remove cover, spring and O-ring -arrow-. –  Do not remove the studs.