Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 3359 Locking pin
• ◆ 3387 Pin wrench
• ◆ T10008 Locking plate
• ◆ T10050 Crankshaft stop
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)

• ◆ 10-222A Support with 10-222A/1 feet
• ◆ Drill bit ø4 mm

Removing

Note:

Adjustment work on toothed belts must be performed on cold engines only.

• ‒ Remove engine cover.
• ‒ Remove connecting pipe between charged air cooler and intake connecting flange.
• ‒ Remove air mass meter.
• ‒ Remove noise insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Assembly overview

• ‒ Disconnect pendulum support at gearbox.
• ‒ Remove ribbed belt .
• ‒ Remove ribbed belt tensioning element.
• ‒ Remove toothed belt guard - upper part.
• ‒ Detach fuel pipe/hose from cylinder head cover.

• ‒ → Fit support device 10-222 A as shown and support engine in its installation position.

• ‒ → Remove bolts from engine mounting -arrows- and remove mounting complete.
• ‒ Remove engine mounting on cylinder block.
• ‒ Remove centre toothed belt guard.
• ‒ Lower engine carefully as far as necessary to remove belt pulley vibration damper.
• ‒ Remove lower toothed belt guard.

• ‒ Turn crankshaft to TDC No. 1 cylinder.

Note:

→ Turn the crankshaft until the mark on the crankshaft pulley is facing up and the arrow on the rear section of the toothed belt guard aligns with lug on the hub sender wheel -arrows-.

• ‒ Lock hub with mandrel 3359. To do this slide mandrel through free elongated hole on left side and into hole in cylinder head.
• ‒ Lock toothed belt crankshaft sprocket using crankshaft stop T10050. To do this, push crankshaft stop from the face side of the toothed belt sprocket into the sprocket's teeth.

Note:

The marks on the crankshaft sprocket and the crankshaft stop must align. At the same time, the shaft of the crankshaft stop must engage in the drilling in the sealing flange.

• ‒ Mark D.O.R. of toothed belt.

• ‒ → Insert a hexagon key into the hexagon hole onto limit stop and press the tensioning roller anti-clockwise -direction of arrow- until the toothed belt tensioning device can be locked with locking plate T10008.

Note:

If the hexagon key is not inserted deeply enough there is a great danger that key will slip and round-off the hexagon drive.

• ‒ Loosen tensioning roller securing nut.

• ‒ Remove toothed belt tensioning device securing bolts -1- and take off tensioning device.
• ‒ Take off toothed belt.

Installing

Note:

Adjustment work on toothed belts must be performed on cold engines only.

• ‒ → Loosen camshaft sprocket securing bolts -1-, until the camshaft sprocket can be moved within the elongated holes.
• ‒ Turn camshaft sprocket in elongated holes clockwise -direction of arrow- onto limit stop.

• ‒ → Now turn the eccentric clockwise carefully with pin wrench 3387 until the eccentric lug lies directly before limit stop -B-.
• ‒ Fit toothed belt onto camshaft sprocket, tensioning roller, crankshaft toothed belt sprocket and the water pump toothed belt sprocket last of all.
• ‒ Install toothed belt tensioning device.

• ‒ → Using pin wrench 3387, turn eccentric anti-clockwise (lug of eccentric moves toward stop -A-) until you can remove locking plate T10008 without placing it under stress.
• ‒ Release force of tensioning element in clockwise direction (lug of eccentric moves toward stop -B-) until distance -a- has been attained.
      Specified distance -a-: 4 ± 1 mm.

Notes:

• ◆ Distance -a- becomes smaller when the tensioning roller securing nut is tightened. Therefore adjust generously using ø 4 mm drill bit.

• ◆ Distance -a- may be reduced to 1 mm if engine is at operating temperature.

• ‒ Hold tensioning roller in this position and tighten tensioning roller securing nut to:
      20 Nm and 45° (1/8 turn further).
• ‒ → Tighten camshaft sprocket securing bolts -1- to 25 Nm.
• ‒ Remove mandrel 3359 and crankshaft stop T10050.

• ‒ Turn crankshaft two rotations in engine D.O.R. and set again to TDC No. 1 cylinder.

Notes:

• ◆ The stub of the crankshaft stop must engage in the sealing flange when turning.
• ◆ If the crankshaft is turned past TDC No. 1 Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in engine direction of rotation again to set it to TDC No. 1 Cyl. It is not permitted to make corrections when turning to ensure the crankshaft stop will engage.

• ‒ Once the crankshaft stop T10050 has engaged, check:
      1.) dimension -a- is ok. and
      2.) the hub can be locked with locking pin 3359.

If dimension -a- is not achieved:

• ‒ Tension the tensioning roller again. To do this, hold tensioning roller with pin wrench 3387, loosen securing bolts and release force of tensioning device until dimension -a- is attained.
      Specified dimension -a-: 4 ±1 mm.
• ‒ Tighten securing nut again to
      20 Nm and 45°(1/8 turn) further.

If the hub cannot be locked:

• ‒ Pull the crankshaft stop pin out of the hole in the sealing flange and turn the crankshaft until the hub can be locked with the locking pin.
• ‒ Loosen camshaft sprocket securing bolts -1-.

• ‒ → Turn crankshaft slightly against engine direction of rotation until the crankshaft stop pin is positioned just before the hole in the sealing flange -arrow-.
• ‒ Now turn the crankshaft in engine direction of rotation until the crankshaft stop pin engages in the sealing flange whilst turning.
• ‒ Tighten camshaft sprocket securing bolts to
      25 Nm.

• ‒ Remove mandrel 3359 and crankshaft stop T10050.
• ‒ Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.

Notes:

• ◆ When doing this the stub of the crankshaft stop must engage in the sealing flange whilst turning.
• ◆ If the crankshaft is turned past TDC No. 1 Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in engine direction of rotation again to set it to TDC No. 1 Cyl. It is not permitted to make corrections when turning to ensure the crankshaft stop will engage.

• ‒ Repeat check.
• ‒ Install lower toothed belt guard and vibration damper/pulley.
• ‒ Install centre toothed belt guard.
• ‒ Fit engine mounting to cylinder block.
      Tightening torque: 45 Nm
• ‒ Install engine assembly mounting.
  Tightening torque => Page 10-13.
• ‒ Install ribbed belt => Page 13-16.
• ‒ Install insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Assembly overview

• ‒ Install top toothed belt guard.
• ‒ Install connecting pipes between air filter and turbocharger and between charge air cooler and intake connecting flange.