Toothed Belt, With A Divided Toothed Belt Guard

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

NOTE:

Vehicles from 01.06 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD and the guard is divided in the engine mount bracket area. Toothed belt without a divided toothed belt guard removing and installing TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD .

Special tools and workshop equipment required

Engine Support Bracket -T10339-
Insert Pad for Front Fender -T40045-, GTI only
Adapter -10-222 A/18-, GTI and Eos only
Bracket For Engine -10-222 A/1-
Torque Wrench (40-200 Nm) -V.A.G 1332-
Engine Support Bridge -10-222 A-

Removing

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

WARNING:

Fuel system is under pressure.

Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
For safety reasons, interrupt the current supply to the fuel pump, refer to SAFETY PRECAUTIONS before opening the fuel system because the fuel pump is activated by the driver door contact switch.

-- Disconnect the lines -1, 2 and 3-. Press the release buttons.

Fig 1: Identifying Fuel Supply Line

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GTI and Eos:

Fig 2: Identifying Ventilation Line & EVAP Canister

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-- Disconnect the ventilation line -2- and pull the Evaporative Emission (EVAP) canister -A- with hoses upward out of the bracket.

Continuation for all Vehicles:

WARNING:

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

-- Open and close the coolant expansion tank cap to reduce the pressure.

-- Loosen the clamp -arrow- and disconnect the coolant hose. Collect leaking coolant with a cloth.

Fig 3: Identifying Coolant Hose Clamp

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-- Disconnect the connector -1-. Loosen the coolant expansion tank bolts -arrows- and lay it on its side.

Fig 4: Identifying Coolant Reservoir Connector & Bolts

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

-- Remove ribbed belt tensioner -A- and secure the bracket -T10339- to both upper threaded holes.

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

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GTI:

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 engine support bridge -10-222 A- with the bracket for engine -10-222 A/1- and the adapter -10-222 A/18- on the fender edges.

-- Install the insert pad for front fender -T40045- as shown under the right and left fender edges. Support the engine in installed position.

Eos:

Fig 7: 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 engine support bridge -10-222 A- with the bracket for engine -10-222 A/1- and the adapter -10-222 A/18- on the fender edges. Support the engine in the installed position.

Passat:

Fig 8: Identifying Rubber Stops For Engine Hood

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-- Remove the rubber stops -arrows- for the hood.

-- Install the engine support bridge -10-222 A- with the bracket for engine -10-222 A/1-, as shown, on the fender edges. Support the engine in the installed position.

Fig 9: Identifying Engine Support Bridge 10-222A Placed With Bracket For Engine 10-222A/1 On Fender Edge

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Continuation for all Vehicles:

CAUTION:

Ensure that the fender edges are not damaged.

-- Remove the upper toothed belt guard bolts -arrows-.

Fig 10: 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 liners.

Fig 11: Identifying Right Front Part Of Wheel Housing Liners

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-- Remove the bolts -arrows- and disconnect the charge air pipe with hoses.

Fig 12: Identifying Charge Air Pipe Bolts

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

Fig 13: Identifying Camshaft Gear Moved To Marking For TDC Cylinder 1

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-- Remove the vibration damper bolts.

Fig 14: Identifying Vibration Damper/Belt Pulley

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NOTE:

The TDC marks must align before removing the vibration damper.

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

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

Fig 15: Identifying Toothed Belt Guard

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-- Identify the TDC position -arrow-.

Fig 16: Identifying TDC Position

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

Fig 17: 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 18: Identifying Wheel Housing Bolt

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NOTE:

The next step is necessary in order to be able to raise the engine far enough.

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

Fig 19: 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 20: 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 the engine using the engine support bridge -10-222 A-.

-- Lift the engine using the engine support bridge -10-222 A- until the upper engine mount bracket bolt -2- can be removed.

Fig 21: Identifying Engine Bracket Bolt

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

Fig 22: Identifying Toothed Belt Guard Upper Bolts

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

-- Mark the rotational direction of the toothed belt, if reinstalling the old belt.

-- Loosen the belt tension and remove the toothed belt.

-- Then, turn the crankshaft back slightly.

Installing

NOTE:

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

The engine must be no more than warm to touch.

For the correct tightening specifications, refer to TOOTHED BELT, WITH A DIVIDED TOOTHED BELT GUARD .

-- Position the camshaft and crankshaft to the TDC mark.

Fig 23: Identifying Check Of Valve Timing

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

-- Route the toothed belt in the sequence: Belt tensioner, camshaft sprocket, coolant pump and lastly under the idler pulley -arrow-.

Fig 24: Identifying Routing Of Toothed Belt

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NOTE:

Be sure the belt tensioner is properly seated in the cylinder head.

Fig 25: Identifying Tensioning Roller Is Properly Seated In Cylinder Head

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-- Tension the toothed belt. To do so, turn the socket head wrench on the eccentric clockwise in the -direction of the arrow- until the notch aligns above the tab (toothed belt excessively tensioned).

Fig 26: Identifying Tensioning Of Toothed Belt

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-- Release the tension on the toothed belt again.

-- Now, tension the toothed belt until the notch and tab align.

-- Tighten the toothed belt tensioner nut to 25 Nm.

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

-- Check the toothed belt tension. Specified value: The tab and notch align.

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

Fig 27: Identifying Check Of Valve Timing

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If the marks do not match:

-- Repeat the valve timing adjustment.

If the marks match:

-- Bring the engine mount bracket into its installed position.

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

Fig 28: Identifying Toothed Belt Guard

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-- Install the vibration damper using new bolts. Tightening specification: 20 Nm + 90° (1/4) additional turn.

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

Fig 29: Identifying Camshaft Gear Moved To Marking For TDC Cylinder 1

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-- Tighten both toothed belt guard upper bolts -arrows-.

Fig 30: Identifying Toothed Belt Guard Upper Bolts

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-- Install the engine mount bracket to the cylinder block and tighten 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 31: Identifying Engine Bracket Bolt

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

-- Tighten all bolts to 45 Nm.

-- Install the engine mount. For the correct tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS .

-- Tighten the engine mount to engine bracket bolts -arrows- hand tight, by bringing the contact surfaces into contact using engine support bridge -10-222 A-.

Fig 32: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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-- Align the engine mount as follows:

There must be a distance of at least 10 mm -a- present between the engine mount bracket -2- and right longitudinal member.

Fig 33: Identifying Casting Edge On Engine Support Location
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The casting edge on the engine mount bracket -2- must be parallel to the engine mount -1-.

-- Tighten the bolts for the engine mount to engine mount bracket. Tightening specification: FASTENER TIGHTENING SPECIFICATIONS .

-- Remove the engine support bridge -10-222 A-.

-- Remove the bracket -T10339- and install the ribbed belt tensioner.

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

-- Reconnect the fuel and ventilation lines. Make sure the connector couplings are securely fastened.

-- Install the coolant expansion tank.

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

-- Restore the interrupted power supply.

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