Volkswagen Workshop Service and Repair Manuals

Removing –  Remove engine cover. –  Remove upper toothed belt guard. –  Mark the direction of rotation of the poly V-belt and remove belt → Chapter.

–  Fit support bracket -10 - 222 A- with frame -10 - 222 A /1- as shown. –  Unbolt cooling system expansion tank and lay to side. –  Unbolt power-assisted steering reservoir and place to side. –  Remove upper securing bolt from lower toothed belt guard beneath engine bracket. –  Take up weight of engine and remove right engine bracket as shown.

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

–  Remove pulley securing bolt and toothed belt pulley. To do this, hold 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 roller on vehicles with air conditioning system. –  Remove lower toothed belt guard.

–  Set crankshaft to TDC No. 1 cylinder. The tooth with end ground down must align with mark on oil pump.

–  The locking pin holes in the camshaft adjuster and the exhaust camshaft pulley 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. Lock camshaft adjuster and exhaust camshaft pulley using locking pin -T10074- as follows:

–  First push locking pin -T10074--A- through locking hole of camshaft adjuster and then push locking pin -T10074--B- through hole in exhaust camshaft pulley into hole in camshaft housing to stop. –  Mark direction of rotation of both toothed belts. Remove main drive toothed belt

–  Loosen main drive tensioning roller using TORX bit set -V.A.G 1766--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. –  Pull locking pin out of camshaft adjuster. –  Remove coupling drive tensioning roller. –  Remove toothed belt.