Volkswagen Workshop Service and Repair Manuals

Removing toothed belt   Note If the toothed belt is renewed during a repair measure, enter this in the service schedule of vehicle wallet.

Golf: t  For safety reasons, remove fuse No. SC 27 from fuse holder on left in dash panel before opening the fuel system if the battery has not been disconnected, otherwise the fuel pump will be activated by the driver door contact switch.

Golf Plus: t  For safety reasons before opening the fuel system, if the battery has not been disconnected, fuse No. SC47 must be removed from fuse holder on left below dash panel, otherwise fuel pump will be activated by driver door contact switch.   WARNING The fuel supply line is pressurized! Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Disconnect breather line -1- as well as fuel line -2-. Lay lines to side.

–  Remove activated charcoal filter with hoses -arrows-. –  Loosen filler neck for washer fluid.

–  Pull off connector -1-. Remove coolant expansion tank and lay it to side.

–  Remove bolts -arrows- and remove toothed belt guard upwards. –  Remove poly V-belt → Chapter.

–  Remove poly V-belt tensioning element -B- and secure the transport bracket -A- again with 3 bolts M8 x 20 on the bracket for ancillaries. Golf Plus:

–  Insert wing compensation plates -T10311- between the wing mounting flange and the apron underneath on both sides of vehicle. t  Installation position: “R”-1- means right side of vehicle. “L” (not illustrated) means left side of vehicle. The arrow -2- always points forwards.   Note When removing the wing compensation plates use hole -3-. All vehicles:

–  Fit engine support bracket -10-222A- with adapters -10-222A/13- and take up weight of engine in installation position. –  Remove noise insulation → General body repairs, exterior; Rep. Gr.50.

–  Remove front right wheel housing liner → General body repairs, exterior; Rep. Gr.66.

–  Set camshaft pulley to TDC marking by turning crankshaft. The marking on camshaft toothed belt pulley must align with arrow on toothed belt guard.

–  Remove belt pulley with vibration damper.   Note t  The TDC markings must align before removing the vibration damper. t  The crankshaft must not be turned until the TDC position is additionally marked.

–  Unscrew bolts from toothed belt guard lower part -arrows-.

–  Mark TDC position -arrow-.

–  Remove lower bolt -3-.   Note The following work step is necessary to raise the engine high enough.

–  Unscrew bolts -2- and -3- from pendulum support.

–  Remove securing bolts from assembly mounting/engine bracket -arrows- and remove complete assembly mounting.   Caution When raising engine using support bracket -10-222A-, ensure that no components or hoses are damaged, strained or torn off.

–  Raise engine with support bracket -10-222A- until both upper bolts -1 and 2- of engine bracket can be loosened and removed.

–  Unscrew the two upper bolts from toothed belt guard -arrows- and remove toothed belt guard from engine downwards. –  Now remove engine bracket from engine upwards. –  Mark direction of rotation of toothed belt. –  Loosen tensioning roller and remove toothed belt. –  Turn crankshaft back slightly.