VW Golf Mk6 Workshop Service & Repair Manuals

Removing »Carry out the following work sequence«   Note Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature. –  Remove engine cover panel → Chapter. –  With ignition switched off, disconnect battery. → Electrical system; Rep. gr.27. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50 –  Remove poly V-belt → Chapter. Golf, Golf Plus, Passat, Touran

–  Remove bolt -1-. –  Push washer fluid reservoir filler pipe with filler neck -2- to side.   Note t  Disregard -item 3-. t  For reasons of clarity, diagram shows installation position with removed fuel filter.

–  Free air guide hose at retainer -2-. –  Pull retainer with fuel hoses off upwards -arrow- and lay to side. –  Disconnect electrical connector -3-. –  Unscrew bolts -1-, lay pressure differential sender -G 505- with bracket aside.

–  Loosen bolt -1-. –  Unscrew bolt -2- and nut -3-. –  Take hose retainer -4- off fuel filter, place fuel filter -7- aside (fuel hoses -5- and -6- remain connected).

–  Remove bolts -arrows-. –  Disconnect electrical connector -1- for coolant shortage indicator switch -F66- and push coolant expansion tank to side.

–  Disconnect electrical connector -3- on radiator outlet coolant temperature sender -G83-. –  Unscrew nut -1- and bolt -2-. –  Free coolant pipe on right along with coolant hoses connected -arrows-.

–  Remove upper toothed belt cover, release clips -arrows- for this. –  Unscrew coolant reservoir and put aside. Polo

–  Disconnect electrical connector -2- at pressure differential sender -G 505-. –  Remove pressure differential sender -G 505- from bracket -3-. –  Lay pressure differential sender -G 505- aside to rear together with lines. Remove fuel filter with bracket.

–  To do this, open quick-release fasteners -A- and -B- of fuel lines. –  Catch any escaping fuel.

–  Use a finger to release locking lug of fuel pre-heater valve. –  Pull fuel pre-heater valve upwards out of coolant expansion tank guide.

–  Unclip fuel filter from lower part of fuel filter. –  Remove fuel filter upwards. –  Separate fuel supply line and return line at engine end. –  Remove fuel filter and fuel lines together with fuel preheater valve. –  Remove fuel filter lower part → Fuel supply; Rep. gr.20.

–  Unscrew bolts -arrows- for coolant expansion tank. –  Disconnect electrical connector -1- for coolant shortage indicator switch -F66-. The coolant expansion tank can thus be placed to one side.

–  Open clips -arrows- and remove toothed belt guard. –  Remove front right wheel housing liner. Continuation for all vehicles: –  Remove vibration damper → Chapter.

–  Remove bolts -arrows-. –  Remove lower toothed belt guard downwards. Polo l  Engine support must be removed to change tensioning roller and to remove and install toothed belt.   Note t  The assembly mounting may only be removed if the engine is supported with support bracket -10-222A-! t  The engine support must only be loosened when the assembly mounting has been removed. –  Remove engine support → Chapter. Continuation for all vehicles:   Note The engine support always also has to be removed in order to change the tensioning roller.

–  Turn engine to TDC and lock crankshaft toothed belt pulley in position with crankshaft stop -T10050-. Fit the crankshaft stop in the teeth from the face side of the toothed belt pulley. l  The mark -2- on the toothed pulley and the arrow -1- on the crankshaft stop -T10050- must align -arrow-. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.

The arrow on the camshaft pulley must be at almost »12 o'clock«. –  Mark direction of rotation of toothed belt.

–  Loosen bolts -arrows- approx. 90° for camshaft toothed belt pulley.

–  Loosen bolts -2- approx. 90° for high-pressure pump toothed belt pulley using bit XZN 10 -T10385-. Tensioning roller A:

–  Loosen securing nut of tensioning roller -1- and turn tensioning roller eccentric using socket -T10264- counter-clockwise -arrow- until tensioning roller can be locked with locking pin -T10265-.

–  Now turn tensioning roller eccentric clockwise -arrow- onto stop and tighten securing nut -1- hand-tight. Tensioning roller B:

–  Loosen nut -1- for belt tensioner. –  Use angled screwdriver 8mm -T10409- to rotate eccentric of tensioning roller clockwise -arrow- until tensioning roller is loosened. –  Re-tighten securing nut hand-tight.   Caution Risk of irreparable damage if direction of rotation is reversed on previously used toothed belt. Before removing toothed belt, mark direction of rotation with chalk or felt tipped pen for installation purposes. –  Remove toothed belt first from idler roller and then from remaining toothed belt pulleys.