Toothed belts, removing, installing and tensioning: Removing

WARNING: This page is about a different car, 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.

NOTE:

Perform adjustment work on toothed belts on cold engines only.

Remove poly V-belt. Refer to Poly V-belt, removing and installing .
Remove tensioning element for poly V-belt.
Remove right headlight: Refer to 94 LIGHTS, SWITCHES - EXTERIOR .
Remove charge air pipe between charge air cooler and exhaust turbocharger. Refer to Charge air cooling components, removing and installing .

Remove coolant expansion tank (coolant hoses remain connected).
Unbolt power steering reservoir and fuel filter and set aside (hoses remain connected).
Disconnect fuel lines from cylinder head cover.

CAUTION:

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen the connection to release the pressure!
Wear eye and hand protection when performing any type of repair work on the fuel system!

Fig 1: Identifying Support Bracket 10-222A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mount engine support bracket 10-222A and take up weight of engine in its installed position.

Fig 2: Identifying Securing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body and assembly mounting/body mounting - arrows - and remove assembly mounting complete.

NOTE:

The assembly mounting may only be removed, if the engine is supported with support device 10-222A !
The engine mounting may only be loosened if the assembly mounting has been removed.

Fig 3: Identifying Engine Mounting Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt engine mounting on cylinder block - arrows - and remove.

NOTE:

When loosening both upper engine mounting bolts the engine must be raised slightly with the support device.
When loosening the lower engine mounting bolt the engine must be lowered slightly with the support device.

Remove vibration damper/belt pulley.
Remove center and lower toothed belt guard.
Turn crankshaft to TDC No. 1 cylinder.

Fig 4: Identifying Locking Pin 3359 And Crankshaft Stop T10050

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Turn the crankshaft so far that the marking on the crankshaft sprocket is at the top and the arrow on the rear toothed belt guard aligns with the lugs on the sender wheel of the hub - arrows -.

Lock hub with locking pin 3359. To do this, slide locking pin through free elongated hole on left side of cylinder head.
Lock crankshaft pulley with crankshaft stop T10050. To do this, push crankshaft stop from face side of toothed belt pulley into pulley teeth.

NOTE:

The marks on the crankshaft pulley and the crankshaft stop must align. At the same time, the pin of the crankshaft stop must engage in the hole in the sealing flange.

Mark direction of rotation of toothed belt.
Loosen tensioning roller securing nut.

Fig 5: Identifying Camshaft Pulley Securing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen camshaft pulley securing bolts - 1 - until camshaft pulley can be moved within elongated holes.

Fig 6: Identifying Pin Wrench 3387 And Locking Pin T10115

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn pin wrench 3387 counter-clockwise (opposite direction of arrow on tensioner) until toothed belt tensioner can be locked in position using locking pin T10115.
Turn pin wrench clockwise (in direction of - arrow - on tensioner) until stop and tighten securing nut hand-tight.
Remove toothed belt first from coolant pump and then from remaining pulleys.