Volkswagen Workshop Service and Repair Manuals

Removing –  Remove engine cover. –  Remove noise insulation tray: → Rep. Gr.50. –  Remove right headlight: → Rep. Gr.94. Vehicles with turbocharger –  Remove air guide pipe between turbocharger and charge air cooler → Item. Continuation for all vehicles –  Remove poly V-belt → Chapter. –  Remove poly V-belt tensioner. Engine installed:

–  Set crankshaft to TDC No.1 cylinder (vehicles with manual gearbox).

–  Set crankshaft to TDC No.1 cylinder (vehicles with automatic gearbox). Engine removed:

–  Set vibration damper to TDC No. 1 cylinder -arrows-. –  Unbolt coolant reservoir and place to side. –  Unbolt power assisted steering reservoir and place to side. –  Pull off vacuum pipes at active charcoal filter and at throttle valve housing. –  Remove upper toothed belt guard. Vehicles with turbocharger

–  Assemble and install support bracket -10 - 222 A- with frame -10 - 222 A /1-. –  Locate bracket -3180- in right lifting eye and bolt on cylinder head then take up weight of engine. Engine code AGN

–  Assemble and install support bracket -10 - 222 A- with frame -10 - 222 A /1-. –  Locate bracket -T10013- in right lifting eye and secure on cylinder head and take up weight of engine.   Note To remove bracket -T10013-, the bracket locking plate must be lifted slightly with a screwdriver. Continuation for all vehicles

–  Remove securing bolts from assembly mounting/engine bracket, assembly mounting/body and assembly mounting/body bracket -arrows- and remove assembly mounting complete.

–  Remove belt pulley with vibration damper. –  Remove toothed belt lower and centre guards. –  Mark direction of rotation of toothed belt.

–  Screw tensioning bolt -T10092- into toothed belt tensioner. –  Align plunger using pointed pliers or thin wire before tensioning, if necessary. (Hole in plunger and hole in housing must align). –  Tension the tensioner plunger until the plunger can be locked with locking pin -T40011-. –  Remove toothed belt. –  Turn crankshaft back slightly.