Toothed belt, removing, installing and tensioning: Removing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2006 Volkswagen GTI, 2005 Volkswagen Jetta, 2005 Volkswagen GTI, 2004 Volkswagen Jetta, and 2004 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Read safety precautions before beginning work refer to Safety precautions when working on fuel supply system .
Observe rules for cleanliness refer to Rules for cleanliness .
Remove engine cover.
Remove sound insulation tray, refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW or NOISE INSULATION (DIESEL ENGINES), ASSEMBLY OVERVIEW .

Remove right headlamp, refer to 94 LIGHTS, SWITCHES - EXTERIOR .
Remove air guide pipe between turbocharger and charge air cooler.
Remove ribbed belt, refer to Ribbed belt, removing and installing under Ribbed belt, removing and installing .
Remove ribbed belt tensioning element.

Engine installed:

Fig 1: Identifying Crankshaft At TDC No. 1 Cylinder (Vehicles With A Manual Transmission)

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position crankshaft at TDC cylinder 1 (vehicles with manual transmission).

Fig 2: Identifying Crankshaft At TDC No. 1 Cylinder (Automatic Transmission)

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position crankshaft at TDC cylinder 1 (vehicles with automatic transmission).

With engine removed:

Fig 3: Identifying Vibration Damper At TDC No. 1 Cylinder

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position vibration damper to TDC cylinder 1 - arrows -.
Remove coolant expansion tank and set aside.
Remove power steering fluid reservoir and set aside.
Remove vacuum line to throttle valve connection.

Remove upper toothed belt guard.

Fig 4: Engine Support Bridge 10 - 222 A Install With Bracket For Engine 10 - 222 A /1

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install engine support bridge 10 - 222 A with bracket for engine 10 - 222 A /1.
Engage Retainer 3180 on right lifting eye and tighten on cylinder head and lightly pre-tension engine.

Fig 5: Locating Securing Bolts From Assembly Mounting/Engine Bracket, Assembly Mounting/Body And Assembly Mounting Bracket/Body

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Remove bolts from subframe/engine bracket, subframe/body and subframe brackets/body - arrows - and completely remove subframe.
Remove engine bracket on cylinder block.

Fig 6: Removing/Installing Vibration Damper/Belt Pulley

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove vibration damper/belt pulley.
Remove lower and middle toothed belt cover.
Mark direction of rotation of toothed belt.

Fig 7: Tensioning Bolt T10092 And Locking Pin T40011 Installed

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install tensioning bolt T10092 into tensioning device for toothed belt.
If necessary, align pressure piston before tensioning using needle nose pliers or a thin wire (hole in pressure piston and hole in housing must line up).
Tension pressure piston of tensioner just enough that the pressure piston can be secured using Locking Pin T40011.
Remove toothed belt.

Turn crankshaft back slightly.