Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Engine support bracket 10-222A with legs 10-222A/1
• ◆ Counter-hold tool 3415
• ◆ Torque wrench V.A.G 1331 (5...50 Nm)
• ◆ Torque wrench V.A.G 1332 (40...200 Nm)

Removing

• ‒ Remove air cleaner:

=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner

The engine must be lowered slightly as follows to enable the crankshaft sprocket to be removed:

• ‒ → Fit support10-222A with legs 10-222A/1 as shown.
• ‒ Take-up weight of engine, and remove right engine mounting.
• ‒ Remove ribbed belt cover.
• ‒ Lower engine until the pulley securing bolt is accessible.
• ‒ Mark the direction of rotation of the ribbed belt and remove belt as follows.

• ‒ → Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
• ‒ Remove ribbed belt.

• ‒ → Remove V-belt pulley and toothed belt sprocket securing bolt. to do this hold the pulley with counter-hold tool 3415.
• ‒ Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt sprocket.
• ‒ Remove toothed belt guard upper and lower parts.
• ‒ Mark D.O.R. of toothed belt.
• ‒ Release tensioner and take off toothed belt.

Note:

If the toothed belt is to be replaced, the console must also be removed.

Installing

Prerequisites

• ● The crankshaft toothed belt sprocket is secured to the crankshaft with the securing bolt and two washers.
• ● The pistons must not be positioned at TDC.

Note:

If a piston is at TDC the valves could strike the piston when turning the camshafts.

Work sequence

• ‒ → Set the camshaft sprockets so that the marks line as shown.

• ‒ → Set the crankshaft to top dead centre No. 1 cylinder. The tooth with end ground down must align with the mark on the sealing flange.
• ‒ Fit toothed belt. For used belts note direction of rotation.

• ‒ → Install tensioning roller and tighten securing nut hand-tight. The slot in the base plate -1- must engage over securing bolt -2- .
• ‒ Tension toothed belt by turning the tensioning roller in direction of arrow until the indicator -3- aligns with the groove in the base plate -arrow-.
• ‒ Tighten clamping nut on tensioning roller.
       Tightening torque: 20 Nm
• ‒ Now turn the crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1 cylinder.
• ‒ Now the position of the toothed belts and tensioning roller must be checked again.
• ‒ Refit toothed belt guard.
• ‒ Refit crankshaft belt pulley. When doing this note the following:
• ‒ The pulley and toothed belt sprocket securing bolt must be renewed.
• ‒ When installing the pulley observe the fixing arrangement to toothed belt sprocket.
• ‒ Tightening procedure for the new oiled bolt: 90 Nm + 1/4 turn (90°) further.
• ‒ Refit right engine mounting with new bolts .
• ‒ Refit the ribbed belt and the cover.

Note:

When installing the ribbed belt ensure that it sits correctly in the pulleys.

• ‒ Check ignition timing:

=> Repair group 28; Injection and ignition system; Checking and adjusting ignition timing.