Volkswagen Workshop Service and Repair Manuals

Removing –  Remove air cleaner housing → Chapter. –  Remove upper toothed belt guard. –  Remove engine splash guard. –  Remove front right wheel housing liner → General body repairs, exterior; Rep. Gr.66 –  Mark the direction of rotation of the poly V-belt and remove belt → Chapter.

–  Position the crankshaft to top dead centre No. 1 cylinder. The notch on the belt pulley must align with the edge of the -O- mark.

–  The locking pin holes in the camshaft pulleys must align with the fitting holes in the camshaft housing -arrows-.   Note If the locking pin holes are positioned to the outside on the toothed belt pulleys, the crankshaft must be turned one revolution further. Fix both camshaft pulleys with camshaft lock -T10016- as follows:

–  Guide both locking pins through camshaft pulley locking pin holes to stop in camshaft housing fitting holes.   Note Both locking pins are inserted correctly when the ends -D- align with line -A-. –  Slide retainer -B- to stop against inlet camshaft pulley -C-. The engine must be lowered slightly as follows to enable the crankshaft pulley to be removed:

–  Fit support bracket -10 - 222 A- with frame -10 - 222 A /1- as shown. –  Unbolt coolant reservoir and place to side. –  Remove upper securing bolt from lower toothed belt guard under engine mounting.

–  Take up weight of engine and remove securing bolts -A-.

–  Remove securing bolts -B- and remove assembly mounting. –  Remove engine bracket on cylinder head. –  Lower engine until the belt pulley securing bolt is accessible.

–  Remove pulley securing bolt and toothed belt pulley. Hold belt pulley with counterhold -3415- and pin 3415/1. –  Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt pulley. –  Remove poly V-belt tensioning element on vehicles with an air conditioning system. –  Remove lower toothed belt guard. –  Mark direction of rotation of both toothed belts. Removing main drive toothed belt

–  Release main drive tensioner -1- and slacken toothed belt by turning tensioning roller anti-clockwise -arrow-. –  Loosen clamping bolt on tensioning roller. –  Remove toothed belt. Removing coupling drive toothed belt

–  Loosen coupling drive tensioner -1- and slacken toothed belt by turning tensioning roller clockwise. –  Remove coupling drive tensioning roller. –  Remove toothed belt.