Volkswagen Workshop Service and Repair Manuals

Installing toothed belt   Note t  When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns. t  The engine must be no more than warm to touch. t  Specified torques → Chapter. –  Fit toothed belt on crankshaft pulley (note direction of rotation). –  Secure toothed belt guard lower part with the two lower bolts. –  Install belt pulley/vibration damper using new bolts. Specified torque: 20 Nm + turn 90° further.

–  Turn crankshaft and camshaft to TDC No. 1 cylinder -arrows-.

–  Fit toothed belt in the sequence: tensioning roller, camshaft pulley, coolant pump and last onto idler roller -arrow-.   Note

Check that tensioning roller is seated correctly in cylinder head.

–  Tension toothed belt. To do so, turn hexagon key at the eccentric adjuster clockwise (direction of arrow) until the notch is above the indicator (toothed belt over-tensioned). –  Then release tension on toothed belt. –  Now tension toothed belt until the notch and the indicator are aligned. –  Tighten securing nut to 25 Nm. –  Turn crankshaft two turns in engine direction of rotation until engine is again at TDC. It is important that the last 45° rotation (1/8 turn) is performed without interruption. –  Check toothed belt tension again. Specification: indicator and notch must align.

–  Check valve timing again. If the markings do not align: –  Repeat valve timing adjustment. If the markings align:

–  Install toothed belt guard -arrows-. –  Install engine support on cylinder block from above and tighten bolts hand-tight.   Note t  Note the different bolt lengths. Bolt -3- is about 25 mm shorter than bolts -1 and 2-.

t  Golf, Eos with engine code BPY and Passat: The bolt -1- can be installed through the hole in wheel housing and tightened. –  Lower engine with support bracket -10-222A- until lower bolt -3- can be tightened. –  Tighten all bolts to 45 Nm. –  Install engine assembly mounting. Specified torques → Chapter.

–  Tighten bolts for engine assembly mounting and engine bracket hand-tight -arrows-; to do so, bring surfaces into contact using support bracket -10 - 222 A-. –  Align engine mountings as follows:

t  There must be a distance -a- of at least 10 mm between engine support and longitudinal member (right side). t  The side surface of the engine support -2- should be located parallel to the support arm -1-. –  Tighten bolts for engine assembly mounting and engine bracket. Specified torques → Chapter –  Remove support bracket -10 - 222 A-. –  Remove bracket -T10339- and install poly V-belt tensioner. –  Install poly V-belt → Chapter. –  Reconnect fuel and breather lines. Ensure that push-on connectors are properly secured. –  Install coolant expansion tank and check coolant level. –  Install noise insulation → General body repairs, exterior; Rep. gr.50. –  Reconnect current supply. –  Install engine cover/air filter.