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 Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Remove right headlight: Refer to 94 LIGHTS, SWITCHES - EXTERIOR
Remove connecting pipe between charge air cooler and intake manifold. Refer to Charge air cooler components, assembly overview .
Loosen coolant expansion tank and set aside.
Remove power steering fluid reservoir and set aside.

Remove upper part of toothed belt cover.
Remove brake booster vacuum pump.
Remove right insulation pan: Refer to 50 BODY, FRONT
Remove ribbed belt. Refer to Ribbed belt, removing and installing .

Fig 1: Identifying TDC For Cylinder 1 (Manual Transmission)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft to TDC for cylinder 1 (on vehicles with manual transmission). - B -

NOTE:

To turn the engine over by hand, use the lever-camber adjustment 3098 and place it on the power steering pump.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft to TDC for cylinder 1 - arrow - (with automatic transmission).

NOTE:

To turn the engine over by hand, use the lever-camber adjustment 3098 and place it on the power steering pump.
With engine removed:

Vehicles with manual transmission

Fig 3: Identifying TDC Mark On The Flywheel Aligned With Tip Of Adjustment Gauge 2068 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten adjustment gauge 2068 A as shown.
Set adjustment gauge to 96 mm - arrow A -. The left notch of the vernier scale is the reference point.
Turn crankshaft until TDC mark on the flywheel is aligned with the tip of the adjustment gauge - arrow B -.

Vehicles with automatic transmission

Fig 4: Identifying TDC Mark On The Crankshaft Aligned With Tip Of Adjustment Gauge 2068 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten adjustment gauge TDC 2068 A as shown.
Set adjustment gauge to 30 mm - arrow A -. The left notch of the vernier scale is the reference point.
Turn crankshaft until TDC mark on drive plate is aligned with the tip of adjustment gauge - arrow B -.

Continue for all vehicles

Fig 5: Identifying Camshaft Bar T10098 & Bolts

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Screw installing bolts - 1 - into cylinder head by hand, up to stop.
Secure camshaft using camshaft bar T10098.

Fig 6: Identifying Injection Pump Sprocket, Rig Pin 3359, Bolts & Nut

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Lock injection pump sprocket with rig pin 3359.
Loosen injection pump sprocket bolts - 1 -.

NOTE:

Unfasten and replace bolts with clearance cut on threaded shaft and point one after the other. (Part No. of injection pump sprocket 038 130 111 A ).
Do not replace bolts without clearance cut on threaded shaft and point. (Part No. of injection pump sprocket 038 130 111 B ).
The nut - 2 - for the hub must not be loosened under any circumstances. Basic setting of the injection pump may be altered and cannot be reset with normal workshop equipment.

Loosen tension roller.

Fig 7: Identifying Support Bracket 10-222A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set engine support bridge 10-222A with bracket for engine 10-222A/1 in place and support engine in installed position.

Fig 8: Locating Securing Bolts From Assembly Mounting/Engine Bracket, Assembly Mounting/Body And Assembly Mounting Bracket/Body

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unfasten bolts from subframe/engine support, subframe/body and subframe brackets/body - arrows - and completely remove subframe.

NOTE:

The subframe may only be removed if the engine is supported by the engine support bridge 10-222A !
The engine support may first be loosened only when the subframe is removed.

Fig 9: Identifying Engine Mounting Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unfasten and remove engine support at cylinder block - arrows -.

NOTE:

To loosen both upper engine support bolts, the engine must be raised slightly with the engine support bridge.
To loosen the lower engine support bolt, the engine must be lowered slightly with the engine support bridge.

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