Volkswagen Workshop Service and Repair Manuals

Installing toothed belt   Note t  When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns. t  The engine must be no more than warm to touch.

–  Set camshaft and crankshaft to TDC markings. –  Place toothed belt on crankshaft pulley (observe DOR).

–  Fit toothed belt in the sequence: tensioning roller, camshaft pulley, coolant pump and last onto idler roller -arrow-.   Note

Check that tensioning roller is seated correctly in cylinder head -arrow-.

–  Tension toothed belt. To do so, turn hexagon key at the eccentric adjuster clockwise (direction of arrow) until the notch is above the indicator (toothed belt over-tensioned). –  Then release tension on toothed belt. –  Now tension toothed belt until the notch and the indicator are aligned. –  Tighten securing nut to 25 Nm. –  Turn crankshaft two turns in engine direction of rotation until engine is again at TDC. It is important that the last 45° rotation (1/8 turn) is performed without interruption. –  Check toothed belt tension again. Specification: indicator and notch must align.

–  Check valve timing. The markings must align -arrows-. If the markings do not align: –  Repeat valve timing adjustment. If the markings align: –  Bring engine bracket to installation position.   Note Do not yet tighten the securing bolts for the engine bracket. The engine bracket must sit “loosely” between engine and longitudinal member.

–  Install toothed belt guard from below -arrows-. –  Install belt pulley/vibration damper using new bolts. Specified torque: 10 Nm + 90° turn further.

–  Check valve timing again: The markings must align -arrows-.

–  Tighten the two upper bolts of toothed belt guard -arrows-. –  Fit engine bracket on cylinder block and tighten upper bolts hand-tight.   Note

Note the different bolt lengths. Bolt -3- is about 25 mm shorter than bolts -1 and 2-. –  Lower engine with support bracket -10-222A- until lower bolt -3- can be tightened. –  Tighten all securing bolts to 45 Nm. –  Lower engine to installation position. –  Install engine assembly mounting. Specified torques → Chapter.

–  Tighten bolts for engine assembly mounting and engine bracket hand-tight -arrows-; to do so, bring surfaces into contact using support bracket -10 - 222 A-. –  Align engine mounting as follows:

t  There must be a distance of -a- at least 10 mm between engine bracket and longitudinal member (right side). t  The side surface of the engine bracket -2- should be located parallel to the support arm -1-. –  Tighten bolts for engine assembly mounting and engine bracket. Specified torques: → Chapter. –  Remove support bracket -10 - 222 A-. –  Install poly V-belt tensioner. –  Install poly V-belt → Chapter. –  Reconnect fuel and breather lines. Ensure that push-on connectors are properly secured. –  Install coolant expansion tank and activated charcoal filter. –  Resecure pendulum support to gearbox. Specified torques → Fig. –  Install front right wheel housing liner → General body repairs, exterior; Rep. Gr.66. –  Install noise insulation → General body repairs, exterior; Rep. Gr.50. –  Refit fuse SC27 (Golf Plus SC47) in fuse holder.