Volkswagen Workshop Service and Repair Manuals

Installing toothed belt Specified torques → Chapter.   Note t  The crankshaft must not be at TDC when the camshaft is rotated (risk of damage to valves/piston crowns). t  The engine must be no more than warm to touch. Carry out the following work:

–  Set camshaft and crankshaft to TDC markings. –  Fit toothed belt on crankshaft pulley (note direction of rotation).

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

Check that tensioning roller is seated correctly in cylinder head.

–  Tension toothed belt; to do this, turn Allen key to right -direction of arrow- until notch is positioned above lug (toothed belt overtensioned). –  Relax toothed belt again. –  Tension toothed belt until notch and lug are positioned opposite each other. –  Tighten securing nut to 25 Nm. –  Turn crankshaft 2 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. 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.

–  Install toothed belt guard from below -arrows-. –  Install vibration damper/belt pulley with new bolts; tightening torque: Turn 10 Nm + 90° further.

–  Check valve timing; the markings must align -arrows-.

–  Tighten both upper bolts of toothed belt guard -arrows-. –  Attach engine bracket to cylinder block and tighten bolts hand-tight.   Note

Note the different bolt lengths. Bolt -3- is about 25 mm shorter than bolts -1 and 2-. –  Tighten lower bolt -3-; to do this, lower engine with support bracket -10 - 222 A-. –  Tighten all bolts to 45 Nm. –  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 mountings as follows:

t  There must be a distance -a- of at least 10 mm between engine support and longitudinal member (right side). t  The side surface of the engine support -2- should be located parallel to the support arm -1-. –  Tighten bolts for engine assembly mounting and engine bracket; tightening torque: → Chapter. –  Remove support bracket -10 - 222 A-. –  Remove bracket -T10339- and install tensioning device for poly V-belt. –  Install poly V-belt → Chapter. –  Reconnect fuel and breather lines; ensure that connector couplings are firmly seated. –  Install coolant expansion tank. –  Install noise insulation → General body repairs, exterior; Rep. gr.50. –  Re-insert fuse for fuel pump control unit -J538- into fuse holder. –  Install engine cover/air filter.