Toothed Belt, With Divided Toothed Belt Guard

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Vehicles from 01.2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover and the guard is divided in the engine mount bracket area. Toothed belt, vehicles without divided toothed belt guard, removing and installing. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Special Tools And Workshop Equipment Required

Engine support bracket T10339
Insert pad for front fender T40045
Adapter 10-222A/18
Bracket for engine 10-222A/1
Engine support bridge 10-222A
Torque wrench (40-200 Nm) VAG 1332

Removing

-- Remove the engine cover/upper air filter housing. Refer to ENGINE COVER/UPPER AIR FILTER HOUSING .

WARNING:

Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by disconnecting the connection.
For safety reasons, disconnect the fuel pump control module electrical connector before opening the fuel system because the fuel pump is activated by the driver's door contact switch.

-- For safety reasons, disconnect the fuel pump control module electrical connector -2- before opening the fuel system.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

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-- Mark the hoses -1 through 3- to the lines.

Fig 2: Identifying Fuel Supply Line Hoses

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-- Open the spring clamps on the lines -1 through 3- and disconnect the hoses.

WARNING:

Hot steam may escape when opening the expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.

-- To release the pressure, open the coolant expansion tank cap and install it again.

-- Disconnect the line from the coolant pipe -arrow-. Collect any leaking coolant with a cloth.

Fig 3: Identifying Coolant Pipe

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-- Disconnect the electrical connector -1-. Remove the coolant expansion tank bolts -arrows- and set it to the side.

Fig 4: Identifying Coolant Reservoir Connector & Bolts

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-- Remove the ribbed belt. Refer to RIBBED BELT .

-- Remove the ribbed belt tensioner -A- and install the T10339 using both upper threaded holes.

Fig 5: Identifying Ribbed Belt Tensioner And Engine Support Bracket T10339

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-- Install the 10-222A with the 10-222A/1 and the 10-222A/18 on the fender edges.

Fig 6: Identifying Engine Support Bridge 10-222A Positioned With Base 10-222A/1 And Adapter 10 - 222 A/18 On Fender Edges

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-- Install the T40045 as shown under the right and left fender edge. Support the engine in the installed location.

CAUTION:

Ensure fender edges are not damaged.

-- Remove the bolts -arrows- and remove the toothed belt guard.

Fig 7: Identifying Toothed Belt Guard Bolts

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-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the right front part of the wheel housing liner.

Fig 8: Identifying Right Front Part Of Wheel Housing Liners

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-- Remove the charge air cooler bolts -arrows- and disconnect the charge air pipe.

Fig 9: Identifying Charge Air Pipe Bolts

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-- Bring camshaft gear to the Top Dead Center (TDC) marking for cylinder 1 by turning crankshaft. The marking on camshaft gear must align with the arrow on the toothed belt guard.

Fig 10: Identifying Camshaft Gear Moved To Marking For TDC Cylinder 1

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-- Remove the vibration damper pulley bolts and pulley.

Fig 11: Identifying Removal/Installation Vibration Damper/Belt Pulley

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NOTE:

The TDC markings must align before removing the vibration damper.

Crankshaft must not be rotated any more until TDC position is marked with an assisting mark.

-- Remove the lower toothed belt guard bolts -arrows- and belt guard.

Fig 12: Identifying Toothed Belt Guard

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-- Identify the TDC position -arrow-.

Fig 13: Identifying TDC Position

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-- Remove the lower engine mount bracket bolt -3-.

Fig 14: Identifying Engine Bracket Bolt

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-- Loosen the bolts for the right wheel housing liner and push it aside.

-- Remove the engine mount bracket bolt -1- through the hole in the wheel housing.

Fig 15: Identifying Wheel Housing Bolt

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NOTE:

The next steps are necessary in order to be able to lift the engine far enough.

-- Remove the pendulum support bolts -2 and 3-.

Fig 16: Identifying Pendulum Support & Bolts

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-- Remove the engine mount to engine mount bracket bolts -arrows- and remove the engine mount completely.

Fig 17: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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CAUTION:

Make sure that no components/hoses are damaged, overstretched or torn when lifting engine using the 10-222A.

-- Raise the engine using the 10-222A until you can loosen and remove the engine mount bracket upper bolt -2-.

Fig 18: Identifying Engine Bracket Bolt

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-- Remove both upper bolts for the toothed belt guard -arrows- and remove the guard downward from the engine.

Fig 19: Identifying Toothed Belt Guard Upper Bolts

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-- Now remove the engine mount bracket upward from the engine.

-- Mark the rotational direction of the toothed belt.

-- Loosen the semi automatic tensioner roller nut and remove the toothed belt.

-- Then, turn the crankshaft back slightly.

Installing

NOTE:

When turning the camshaft, the crankshaft must not be at TDC. Valves and/or pistons may be damaged.

The engine must be no more than warm to touch.

-- Set the crankshaft and camshaft to TDC -arrows-.

Fig 20: Identifying Check Of Valve Timing

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-- Place the toothed belt onto the crankshaft gear (observe the direction of rotation).

-- Route the toothed belt in the sequence: Semi automatic tensioner roller, camshaft gear, coolant pump and lastly around the damper pulley -arrow-.

Fig 21: Identifying Routing Of Toothed Belt

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NOTE:

Be sure the semi automatic tensioner roller is properly seated in the cylinder head.

Fig 22: Identifying Tensioning Roller Is Properly Seated In Cylinder Head

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-- Tension the toothed belt. To do so, install the wrench on the eccentric and turn it clockwise in the -direction of the arrow- until the notch is above the tab (toothed belt excessively tensioned).

Fig 23: Identifying Tensioning Of Toothed Belt

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-- Release the tension on the toothed belt again.

-- Tension the toothed belt until the notch and tab align.

-- Tighten the semi automatic tensioner roller nut.

Tightening specification: 25 Nm

-- Rotate crankshaft two additional turns in the direction of engine rotation until the engine again is at TDC. For this it is necessary that the last 45° (1/8 rotation) is turned without interruption.

-- Check the tension on the toothed belt again.

Specified value: Tab and notch align.

-- Check the valve timing. The markings must align -arrows-.

Fig 24: Identifying Check Of Valve Timing

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If the markings do not match:

-- Repeat the valve timing adjustment.

If the markings match:

-- Install the toothed belt guard from below and install the bolts -arrows-.

Fig 25: Identifying Toothed Belt Guard

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-- Install the vibration damper pulley with new bolts.

Tightening Specification

Strength category 8.8: 10 Nm + 90° (1/4) additional turn
Strength category 10.9: 20 Nm + 90° (1/4) additional turn

-- Check the valve timing again: The markings must align -arrows-.

Fig 26: Identifying Camshaft Gear Moved To Marking For TDC Cylinder 1

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-- Install and tighten both upper bolts -arrows- for the toothed belt guard.

Fig 27: Identifying Toothed Belt Guard Upper Bolts

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-- Install the engine mount bracket to the cylinder block from above and tighten the bolts hand tight.

NOTE:

Note the different length of bolts. Bolt -3- is approximately 25 mm shorter than bolts -1 and 2-.

Bolt -1- can be installed and tightened through the hole in the wheel housing.

Fig 28: Identifying Engine Bracket Bolt

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-- Lower the engine using 10-222A far enough until the lower bolt -3- can be tightened.

-- Tighten all bolts.

Tightening specification: 45 Nm

-- Lower the engine to the installed position.

-- Install the engine mount completely. Tightening specification, refer to FASTENER TIGHTENING SPECIFICATIONS .

-- Install the engine mount to engine mount bracket bolt -arrows-. To do so, bring the contact surfaces into contact using the 10-222A.

Fig 29: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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-- Checking and adjusting the engine mount, refer to one of the following:

ENGINE MOUNT ADJUSTMENT, CHECKING .

ENGINE AND TRANSMISSION MOUNT, ADJUSTING .

-- Remove the 10-222A.

-- Install the ribbed belt. Refer to RIBBED BELT .

-- Reconnect the fuel, ventilation and vacuum hoses.

-- Install the coolant expansion tank.

-- Install the noise insulation. Refer to Description and Operation .

-- Install the engine cover/upper air filter housing.

-- Connect the fuel pump control module electrical connector -2-.

Fig 30: Identifying Cover With Fuel Pump Control Module J538

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