Volkswagen Workshop Service and Repair Manuals

Removing toothed belt –  Remove engine cover/air filter → Chapter.   WARNING The fuel system is pressurised! t  Wear eye protection and protective clothing to avoid possible injury and skin contact. t  Before loosening line connections, wrap a cloth around the connection. Then release pressure by carefully pulling off line. t  For safety reasons, the fuse for the fuel pump must be removed before opening the fuel system → Chapter. Otherwise, the fuel pump could be activated by the driver door contact switch.

Engine code BPY: –  Disconnect lines -1, 2 and 3-. Do this by operating release buttons.

Engine codes AXX, BWA –  Disconnect breather line -1- and fuel supply line -2-.

Golf, Eos: –  Disconnect breather line -2-. Pull activated charcoal filter -A- with hoses upwards out of bracket. Continuation for all vehicles:   WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. –  Open coolant expansion tank to release pressure and close again.

–  Release clamp -4- and detach coolant hose. Collect escaping coolant with a cloth.

–  Pull off connector -1-. Remove coolant expansion tank and lay it to side. –  Remove poly V-belt → Chapter.

–  Remove poly V-belt tensioner -A- and secure bracket -T10339- to both upper threaded holes.

Golf: –  Fit support bracket -10-222A- with rack -10-222A/1- and adapter -10 - 222 A /18- on wing edges. –  Place the wing compensation plate -T40045- below the right and left wing edge as shown. Take up weight of engine in its installation position.

Eos: –  Fit support bracket -10-222A- with rack -10-222A/1- and adapter -10 - 222 A /18- on wing edges. Take up weight of engine in its installation position.

Passat: –  Remove stop buffers for bonnet -arrows-.

–  Fit support bracket -10-222A- with rack -10-222A/1- on wing edges as shown. Take up weight of engine in its installation position. Continuation for all vehicles:   Caution Ensure that the edges of the wings are not damaged. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Remove right wheel housing liner front part.

–  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-. Golf, Eos with engine codes BPY and Passat: –  Loosen bolts of right wheel housing liner and push to side.

–  Remove bolt -1- through hole in wheel housing. Continuation for all vehicles:   Note Following work steps are necessary to raise the engine high enough.

–  Loosen front exhaust pipe with catalytic converter from turbocharger -arrows-. –  Pull catalytic converter from turbocharger.

–  Unscrew bolts -2- and -3- at pendulum support. –  Disconnect drive shafts from gearbox → Running gear, axles, steering; Rep. gr.40

–  Loosen pipes of air conditioning system from body -arrows-.   Note Do not open air conditioning system!

–  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 the upper bolts -1- (only engine code AXX, BWA) and -2- of engine bracket can be loosened and removed. –  Lift engine further, until the engine bracket can be removed upwards.

–  Unscrew 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.