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.

–  Remove engine cover, if fitted.

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. All vehicles:   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 poly V-belt and remove locking pin -T10060A- → Chapter. 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.

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

–  Remove lower bolt -3-.   Note Following work steps are necessary to raise the engine high enough.

–  Remove securing nuts -arrows- for front exhaust pipe to exhaust manifold.

–  Unscrew bracket for exhaust system -arrows-.

–  Unscrew bolts -2- and -3- from pendulum support. –  Disconnect drive shafts from gearbox → Running gear, axles, steering; Rep. Gr.40 Vehicles with air conditioning:

–  Loosen air conditioning system pipes from body.   Note Do not open air conditioning system! Continuation for all vehicles:

–  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. –  Lift engine further, until the engine bracket can be removed upwards.

–  Remove remaining bolts from toothed belt guard -arrows- and remove toothed belt guard from engine. –  Mark direction of rotation of toothed belt. –  Loosen tensioning roller and remove toothed belt. –  Turn crankshaft back slightly.