Volkswagen Workshop Service and Repair Manuals

Removing   Caution When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  To avoid damage to lines, ensure sufficient clearance to all moving or hot components. –  Remove air filter housing (engine code BCA) → Fig.. –  Remove upper guard for toothed belt. –  Remove engine splash protection. –  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 crankshaft at 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-.

–  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 lower toothed belt guard.

–  Fit engine support bracket -10-222A- with adapters -10-222A/8- as shown and take up weight of engine in installation position.

–  Pull activated charcoal filter -1- out of bracket. –  Unscrew filler neck for window wash system.

–  Unbolt bracket for activated charcoal filter from engine mounting -arrows-. –  Unbolt coolant expansion tank and lay to side (hoses remain connected).

–  Remove securing bolts -A-, -B- and -C- from assembly mounting on pulley end and remove complete assembly mounting. –  Remove engine bracket on cylinder head. –  Mark direction of rotation of both toothed belts. Remove 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.