Volkswagen Workshop Service and Repair Manuals

Removal –  Remove air filter body: → Rep. Gr.24 –  Remove mechanical distribution upper cover. –  Remove lower engine anti-noise. → Body - External assembly jobs; Rep. Gr.50 –  To remove crank shaft pulley, lower engine a bit in the following way:

–  Install device 10-222A with support 10-222A/1 as indicated. –  Remove upper bolt of mechanical distribution lower cover. –  Lift engine a bit and remove engine support.

–  Remove bolts A and B from support. –  Mark Poly-V belt operation direction.

–  Displace tension pulley in -arrow- direction to loosen Poly-V belt using screwdriver e/c 16. –  Remove Poly-V belt or install it. –  Lower engine so that it is possible to remove crank shaft pulley.

–  Loosen fastening bolt from pulley/crank shaft gear. For that, use tool 3415 and 3415/1. –  Remove pulley. To fasten crank shaft gear, install fastening bolt. –  In vehicles with air conditioning, remove Poly-V belt tension pulley. –  Remove mechanical distribution lower cover.

–  Place crank shaft on cylinder 1 upper neutral position. Chamfered dent must be aligned with mark 4V on flange/oil pump.

–  Valves command shaft gear immobilizing holes must align with holes on head cover -arrows-.   Note t  If markings are not aligned, it is necessary to turn crank shaft once more. t  Immobilize valve command shaft gear with Camshaft clamp -T10016-, as shown below:

–  Install both retaining rods on valve command gear holes until they fit into head holes.   Note Retaining rods will be properly aligned when ends -D- are aligned as per line -A-. –  Lean support -B- until it touches intake valve command shaft gear -C-. –  Mark with -arrow- the operation direction of indented belts. Remove main indented belt

–  Loosen main indented belt tension pulley with TORX-key set -V.A.G 1766/--1- and loosen indented belt turning tension pulley counter clockwise-arrow-- . –  Loosen tension pulley fastening bolt. –  Remove indented belt Remove indented belt of valves command shaft

–  Loosen indented belt tension pulley of valve command shaft -1- and loosen indented belt turning tension pulley clockwise. –  Remove retaining rods of valve command shaft gears. –  Remove indented belt.