Toothed belt, removing, installing and tensioning: Installing

WARNING: This page is about a different variant/trim than selected.

Verify that the TDC mark on flywheel and reference mark are aligned.
Loosen camshaft sprocket bolt by one revolution. To loosen bolt, counterhold camshaft sprocket using counter-holder 3036.

NOTE:

When loosening and tightening the camshaft sprocket, never use the camshaft bar T10098 to counter-hold! Use the counter-holder 3036.

Fig 1: Identifying Puller T40001 With The One-Armed Claw T40001/2 & Two-Armed Claw T40001/3, Camshaft Sprocket & Open-End Wrench

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set puller T40001 with the one-armed claw T40001/2 - A - and the two-armed claw T40001/3 - B - centering onto the camshaft sprocket and pull it off. To counter-hold, use an open-end wrench - C -.
Place toothed belt onto crankshaft sprocket, idler roller, injection pump sprocket, coolant pump sprocket and tensioner roller (observe direction of rotation).
Align injection pump sprocket to centering location in slots.
Install camshaft sprocket together with toothed belt and fix them in place with bolt (camshaft sprocket can still be turned).

Fig 2: Identifying Toothed Belt Notch And Protrusion

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tension the toothed belt. Do this by turning the pin wrench V159 on eccentric in a clockwise direction, until notch and projection - arrows - are aligned.

NOTE:

In case the eccentric was turned past the marks, the tension roller must be completely relieved of tension, and then be tensioned again. If turned too far, the eccentric must not just be turned back again to the passed mark.

Fig 3: Identifying Tensioning Roller

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Make sure the tensioning roller is properly positioned in the rear toothed belt guard - arrow -.

Fig 4: Identifying Securing Bolts For Injection Pump Sprocket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Version - A - : Bolts with clearance cut on thread shaft and point - arrows -.

NOTE:

After the automatic test of the start of injection, the bolts must be turned an additional 90 ° (1/4 turn).
The bolts may only be used once, since they are bolts with reduced shanks.

Version - B - : Securing bolts without clearance cut on thread shaft and point.

NOTE:

Continue for all versions

Remove camshaft bar T10098 from camshaft.
Remove rig pin.
Turn crankshaft over twice in engine running direction and then set cyl. 1 to TDC again.
Verify that the TDC marking on the flywheel, the camshaft bar in the camshaft, the rig pin in the injection pump, the adjustment of the tension roller (notch/protrusion) or (notch/arrow) are positioned properly.

If notch and protrusion or notch and arrow are not aligned, tension the tension roller again and tighten nut to 20 Nm.
Continue turning crankshaft two rotations in direction of engine rotation until crankshaft is again at TDC for cylinder 1.
Check again.

Fig 5: Identifying Engine Mounting Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set engine support in place at cylinder block and fasten - arrows -. Torque specification: 45 Nm

NOTE:

Before the subframe can be installed, all bolts for the engine supports must be tightened to the specified torque.

Install subframe engine/body (replace bolts). Torque specification: 40 Nm plus an additional 90 ° ( ¹ / ₄ turn)
Align subframe, engine side. Refer to Engine and transmission mounts, aligning .
Tighten engine subframe to engine support, bringing contact surfaces together using engine support bridge 10-222 A. Torque specification: 100 Nm
Align subframe, engine side. Refer to Engine and transmission mounts, aligning .

Install toothed belt cover and vibration damper/belt pulley.
Install ribbed belt. Refer to Ribbed belt, removing and installing .
Install noise insulation pan.
Install connecting pipe between charge air cooler and intake manifold. Refer to Charge air cooler components, assembly overview .

Install right headlight: Refer to 94 LIGHTS, SWITCHES - EXTERIOR
Check headlight adjustment, correct if necessary.
Check injection pump for start of injection: Refer to 23 DIESEL FUEL INJECTION for M.Y. 99-01, or 23 DIESEL FUEL INJECTION from M.Y. 2002 and on