Toothed Belt, From 06.05

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Rig pin 3359
Drift T10060 A
Crankshaft stop T10100
Counter-holder tool T10172
Socket wrench T10264
Locking tool T10265

Removing

NOTE:

Observe safety precautions FUEL SUPPLY SYSTEM SAFETY PRECAUTIONS .

-- Turn the ignition and all electrical consumers off and remove the ignition key.

-- Remove engine cover.

One Piece Engine Cover

Fig 1: Identifying Removal Of One Piece Engine Cover

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Pull the one piece front engine cover -arrows A- upward with a quick jerk and then pull the lower mount -arrow B- forward.

Two Piece Engine Cover

Fig 2: Identifying Removal Of Two Piece Engine Cover

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On the two piece engine cover, first pull the outer cover upward with a quick jerk -arrows in the upper illustration-, then pull the inner engine cover upward with a quick jerk -arrows in lower illustration-.

WARNING:

The temperature of the fuel lines as well as the fuel can, in extreme cases, go up to 100 °C on vehicles equipped with a PD engine. Before opening any line connections, let the fuel cool down otherwise you could get burned.
Wear protective gloves.
Wear safety glasses.

-- Disconnect the fuel supply hose -2- and the fuel return hose -1- from the fuel lines.

Fig 3: Identifying Fuel Return Hose -1-, Fuel Supply Hose -2- And Coolant Line -3-

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-- Disconnect the coolant line -3-.

-- Remove bolts -1-.

-- Remove the connecting pipe between the charge air cooler and the intake connection; while doing this, slightly lift the clips -arrows-.

Fig 4: Identifying Bolts To Remove Connecting Pipe

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-- Disconnect the fuel supply line -3- and the fuel return line -2- ; while doing this pull the release buttons.

Fig 5: Identifying Fuel Supply Line, Fuel Return Line & Coolant Hose

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Fuel Filter Without the Retaining Plate

-- Release the clips and remove the fuel filter with the hoses still connected from the retaining plate -arrow-.

Fig 6: Identifying Fuel Filter Pulled Out Of Bracket

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Fuel Filter With the Retaining Plate

-- Loosen the bolt -1- one turn.

Fig 7: Identifying Bolt And Nut

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-- Remove the bolt -2- and the nut -3-.

-- Remove the fuel filter with the hoses still connected.

Continuation for All

-- Remove the bolt on the fuel filler tube -2- for the washer fluid reservoir.

Fig 8: Identifying Coolant Expansion Tank -1-, Fuel Filler Tube -2- And Retaining Plate -3-

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-- Remove the retaining plate -3- for the fuel filter, if equipped.

-- Disconnect the electrical connectors on the coolant expansion tank -1-.

-- Remove coolant expansion tank with the hoses still connected. Lay it on the engine.

-- Remove ribbed belt RIBBED DRIVE BELT .

-- Remove the ribbed belt tensioning element.

-- Remove the upper toothed belt guard; to do this, loosen the clips -arrows-.

Fig 9: Identifying Clips To Upper Toothed Belt Guard

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-- Remove front right wheel housing liner.

-- Remove vibration damper/belt pulley.

-- Remove the lower and center toothed belt guard.

-- Turn crankshaft to set cylinder 1 at TDC.

NOTE:

When doing so, turn the crankshaft so that the marking on the crankshaft toothed belt gear and the tooth segment of the camshaft gear are positioned upward. The marking on the rear toothed belt guard must align with the marking on the camshaft sensor wheel -arrow-.

Fig 10: Identifying Rig Pin 3359 To Lock Hub And Crankshaft Stop T10100 To Lock Toothed Belt Crankshaft Sprocket

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-- Lock the hub with the rig pin 3359. To do this, push the rig pin through the left-sided empty slot in the bore of the cylinder head.

-- Also, lock the toothed belt crankshaft sprocket with the crankshaft stop T10100. Push the crankshaft stop from the front side of the toothed belt sprocket into the teeth.

NOTE:

Markings on toothed belt crankshaft sprocket and the crankshaft stop must be aligned. The tab of the crankshaft stop must engage in the bore of the sealing flange.

-- Mark rotational direction of toothed belt.

-- Loosen the bolts -1- of the camshaft sprockets, until the camshaft sprocket can be turned in the slots.

Fig 11: Identifying Camshaft Pulley Securing Bolts

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-- Loosen the nut -1- of the tensioning roller.

Fig 12: Identifying Tools To Loosen Nut From Tensioning Roller

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-- Turn the tension roller eccentric pulley using socket wrench T10264 counterclockwise -arrow-, until the securing pin T10265 can lock the tension roller.

-- Now turn the tensioning roller eccentric pulley clockwise -arrow- all the way and tighten the nut -1- by hand.

Fig 13: Identifying Tools To Tighten Nut To Tensioning Roller

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-- First, take the toothed belt from the coolant pump and then from the remaining toothed belt gears.

Installing

Camshaft is secured with the rig pin 3359.
Crankshaft locked with crankshaft stop T10100.
Tensioning roller secured with pin T10265 and seated on right stop with the nut.

NOTE:

Adjustments to toothed belt may generally only be performed when the engine is cold, because the indicator position of the tensioning element changes depending on engine temperature.

-- Turn the camshaft sprocket in its slots -arrows- to middle position.

Fig 14: Identifying Toothed Belt Fitted On Crankshaft Toothed Belt Sprocket, Tensioning Roller, Camshaft Sprocket, Idler Wheel And Coolant Pump

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-- Install the toothed belt through the space between the engine mount and the engine.

-- Place the toothed belt onto the crankshaft sprocket, tensioning roller, camshaft sprocket and idler roller.

-- Lastly, lay the toothed belt onto the toothed belt coolant pump sprocket.

NOTE:

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

Fig 15: Identifying Rear Toothed Belt Guard

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-- Pull the locking pin T10265 out from the tensioning roller.

-- Loosen the nut -1- of the tensioning roller.

-- Turn the tensioning roller eccentric pulley using the socket wrench T10264 clockwise -arrow-, until the indicator -2- is located centrally in the gap of the base plate.

Fig 16: Identifying Socket Wrench T10264 To Loosen Nut Of Tensioning Roller

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NOTE:

Make sure that the nut does not turn along with it.

-- Hold the tensioner roller in this position and tighten the nut to 20 Nm + 45° (¹ /₈ turn).

-- Mount the counter-holder tool T10172 with the bolt T10172/4 as shown in the illustration, and hold the toothed belt tensioned by pushing in -direction of arrow-.

Fig 17: Identifying Counter-Holder Tool T10172 And Bolt T10172/4 To Tighten Camshaft Sprocket Bolts

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-- Tighten the camshaft sprocket bolts -1- to 25 Nm.

-- Remove the rig pin 3359 and the crankshaft stop T10100.

-- Turn the crankshaft 2 turns in the direction of the engine, until the crankshaft is once again just in front of TDC.

-- Lock the hub with the rig pin 3359 from the rotating movement in engine rotation direction.

Fig 18: Identifying Toothed Belt Fitted On Crankshaft Toothed Belt Sprocket, Tensioning Roller, Camshaft Sprocket, Idler Wheel And Coolant Pump

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-- Check if the crankshaft can be locked with the crankshaft stop T10100.

Fig 19: Identifying Rig Pin 3359 To Lock Hub And Crankshaft Stop T10100 To Lock Toothed Belt Crankshaft Sprocket

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If the crankshaft cannot be locked:

-- Loosen the bolts -1- of the camshaft sprocket.

Fig 20: Identifying Camshaft Pulley Bolts

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-- Turn the crankshaft against the engine running direction until the crankshaft stop tab is positioned shortly before the sealing flange bore -arrow-.

Fig 21: Identifying Removal Of Rig Pin 3359 And Crankshaft Stop T10100

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-- Now turn the crankshaft in engine running direction until the crankshaft stop tab engages the sealing flange.

-- Install the counter-holder T10172 with pins T10172/4 as shown. Push the counter-holder T10172 in direction of arrow and hold the camshaft sprocket pre-tensioned.

Fig 22: Identifying Counter-Holder T10172 To Tighten Camshaft Sprocket Securing Bolts

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-- In this position, tighten the camshaft sprocket bolts -1- to 25 Nm.

-- Remove the rig pin 3359 and the crankshaft stop T10100.

-- Continue turning crankshaft two rotations in direction of engine rotation until the crankshaft is shortly before TDC for cylinder 1.

-- Repeat the inspection and adjust if necessary.

-- Install the lower and center toothed belt guard.

-- Install the vibration damper/belt pulley. Tightening specifications 10 Nm + 90° (1/4 turn) further

-- Install ribbed belt RIBBED DRIVE BELT .

-- Install upper toothed belt guard.

-- Install the connecting tube between the charge air cooler and intake connection.

-- Install the front right wheel housing liner.

-- Install the coolant expansion tank.

-- Install the fuel filter.

-- Tighten the filler tube for the windshield washer.

-- Install the engine cover.