Engine codes AEG, AVH, AZG, BEV

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Engine code BBW. Refer to Engine code BBW

Fig 1: Identifying Special Tools - Toothed Belts (Engine Codes AEG, AVH, AZG, BEV)

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(Adjusting valve timing)

Special tools and equipment

10-222A Engine support bracket with legs 10-222A/1
T10004 Two hole pin wrench
V.A.G 1331 Torque wrench (5 to 50 Nm)
V.A.G 1332 Torque wrench (40 to 200 Nm)

Removing

Remove engine cover.
Remove right side sound insulation.

Refer to BODY, FRONT

Remove poly V-belt. Refer to Poly V-belt, removing and installing .
Remove tensioning element for poly V-belt.
Remove coolant expansion tank (supply hose remains connected, close union for return supply hose).
Remove power steering reservoir (hoses remain connected).

Remove toothed belt guard upper part.

Fig 2: Aligning Mark On Camshaft With Mark On Toothed Belt Cover

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Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft pulley must align with (arrow) on toothed belt guard.

Fig 3: Mounting Support 10-222A With Legs 10-222A/1

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Mount support 10-222A with legs 10-222A/1 as shown.

Fig 4: Locating Securing Bolts From Assembly Mounting/Engine Bracket, Assembly Mounting/Body And Assembly Mounting Bracket/Body

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Remove securing bolts from assembly mounting/engine bracket, assembly mounting/body and assembly mounting bracket/body (arrows) and remove assembly mounting complete.

Fig 5: Removing/Installing Vibration Damper/Belt Pulley

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Remove vibration damper/belt pulley.

Fig 6: Identifying Engine Bracket-To-Cylinder Head Bolts

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Remove engine bracket from cylinder head.

NOTE: When loosening the front engine mounting bolt the engine must be raised slightly with the support device.

Remove toothed belt guard center and lower parts.
Mark direction of rotation of toothed belt.
Release tensioner and take off toothed belt.
Turn crankshaft back slightly.

Installing

Requirements

Pistons must not be positioned at TDC.

Work sequence

Place toothed belt on crankshaft pulley and coolant pump pulley (observe direction of rotation).

NOTE:

With engine removed:
Install lower toothed belt guard and vibration damper/belt pulley.

Adjusting valve timing

NOTE: When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.

Fig 7: Aligning Mark On Camshaft With Mark On Toothed Belt Cover

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Align mark on camshaft with mark on toothed belt cover.

Engine installed:

Fig 8: Identifying Crankshaft At TDC No. 1 Cylinder (Vehicles With A Manual Transmission)

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Turn crankshaft to TDC No. 1 cylinder (vehicles with a manual transmission).

Fig 9: Identifying Crankshaft At TDC No. 1 Cylinder (Vehicles With A Automatic Transmission)

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Turn crankshaft to TDC No. 1 cylinder (vehicles with an automatic transmission).

With engine removed:

Fig 10: Identifying Vibration Damper At TDC No. 1 Cylinder

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Position vibration damper at TDC No. 1 cylinder (arrows).
Installed toothed belt on tensioning roller and camshaft pulley.

Tensioning toothed belt

Requirements

Engine must be no more than warm to the touch.
Camshaft pulley positioned at TDC for cylinder 1.
Before tensioning toothed belt, turn tensioning roller 5 times on to limit stop (in both directions) at eccentric using pin wrench T10020.

Work sequence

Fig 11: Releasing Tension On Toothed Belt Until Notch And Indicator Align (Engine codes AEG, AVH, AZG, BEV)

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Tension toothed belt by turning eccentric to left (direction of arrow) with two hole pin wrench (T10020) onto limit stop.
Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).
Tighten securing nut to 20 Nm.
Turn crankshaft two rotations in engine direction of rotation and set again to DTC No. 1 cylinder. When doing this it is important that last 45 ° (1/8 turn) is completed without interruptions.

Check tension of toothed belt again.

Specification: Indicator and notch align

Continued for completing installation of toothed belt

Install center and lower toothed belt guard
Install vibration damper/belt pulley.

Tightening torque: 25 Nm

Install engine mounting to cylinder block.

Tightening torque: 45 Nm

Install engine assembly mounting complete.

NOTE: Insert bolts into engine bracket before installing bracket

Align assembly mountings for engine and transmission. Refer to Engine and transmission mountings, aligning .
Assembly mounting torque settings. Refer to Assembly mounting
Remove engine support device 10-222 A.
Install toothed belt guard upper part.

Install poly V-belt tensioning element.

Tightening torque: 25 Nm

Install poly V-belt. Refer to Poly V-belt, removing and installing .
Install coolant expansion tank.
Install power steering reservoir.
Install right side sound insulation:

Refer to BODY, FRONT

Check engine oil level and top up, if necessary.
Install engine cover.