Toothed Belt, Through 05.05

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

Securing pin 3359
pin wrench T10020
Securing pin T10115
Crankshaft stop T10050 for round crankshaft toothed belt gear
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine support bridge 10 - 222 A
Adapter 10 - 222 A/3
Adapter 10 - 222 A/8
Spring-type clip pliers VAS 5024A
Crankshaft stop T10100 for oval crankshaft toothed belt gear
counter-holder T10172 with
Adapter 10-222 A20

Removing

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.

-- 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-.

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

-- Remove coolant expansion tank. The hoses remain connected.

-- Remove ribbed belt RIBBED DRIVE BELT .

-- Remove the ribbed belt tensioning element.

-- Remove the pin from the ribbed belt tensioning element.

-- Remove the front rear wheel housing liner Removal and Installation .

-- Remove the charge air tube between the charge air cooler and turbocharger TURBOCHARGER ASSEMBLY OVERVIEW .

NOTE:

Seal off the openings of the charge air circuit carefully, e.g. with a clean cloth, to prevent the entry of dirt particles.

-- Remove vibration damper.

-- Unbolt the lower and middle toothed belt cover -arrows-.

Fig 3: Identifying Bolts Of Lower And Middle Toothed Belt Cover

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-- Attach the engine support bridge 10 - 222 A with the frame 10 - 222 A/8 and adapter 10 - 222 A/3 and adapter 10 - 222 A/16 in front of the hood gas-filled strut.

Fig 4: Identifying Engine Support Bridge 10-222 A And Accessories

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-- Hook the carabiner hooks of the spindles into the lifting eyes. Use the adapter 10 - 222 A/20 on the right side as well.

-- Uniformly preload engine using both spindles, do not raise.

NOTE:

If the toothed belt is removed for removing the cylinder head, mount the engine support bridge 10-222 A with the higher adapters 10-222 A/13 ONLY VEHICLES THROUGH 05.05 . This way there is enough space to remove the cylinder head.

-- Unscrew the bolts -arrows- from the engine mount and remove the mount completely.

Fig 5: Identifying Securing Bolts

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NOTE:

The subframe may only be removed if the engine is supported by the engine support bridge 10 - 222 A!

The engine bracket may first be loosened only when the subframe is removed.

-- Lift the engine with the engine support bridge 10 - 222 A slightly so that both upper bolts -arrows- of the engine bracket can be loosened.

Fig 6: Identifying Engine Bracket 10-222A Bolts

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-- Lower the engine using the engine support bridge 10 - 222 A slightly so that the lower bolt -arrow- of the engine bracket can be loosened.

-- Remove the refrigerant line mounting clamp from the longitudinal member.

-- Remove the engine bracket to the rear and out.

-- Turn crankshaft to set cylinder 1 at TDC.

NOTE:

Phased in introduction of oval crankshaft toothed belt gears. If equipped with this toothed belt gear, it must be secured with the crankshaft stop T10100 to determine TDC.

Fig 7: Identifying Crankshaft Toothed Belt Gear Identification

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A = round toothed belt gear, secure with crankshaft stop T10050, TDC marking at "12 o'clock"

B = oval toothed belt gear, secure with crankshaft stop T10100, TDC marking at "1 o'clock"

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 cover must align with the marking on the camshaft sensor wheel -arrow-.

Fig 8: Identifying Rear Toothed Belt Cover Aligned With Marking On Camshaft Sensor Wheel

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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 9: Identifying Camshaft Pulley Securing Bolts

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-- Loosen the nut of the tensioning roller.

NOTE:

Phased in introduction of a new toothed belt tensioning roller. The tensioning roller has an additional internal hex -arrow-. To tension/relieve the toothed belt, use a internal hex key instead of the toothed belt tensioner T10020. The work procedure does not change due to this.

Fig 10: Identifying Tensioning Roller Additional Hex Bit

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-- Turn the toothed belt tensioner T10020 counterclockwise until the toothed belt tensioning roller can be locked with the locking pin T10115.

Fig 11: Identifying Tensioning Roller Turned Counter-Clockwise With Pin Wrench T10020 Or T10004 To Lock With Pin T10115

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-- Turn the toothed belt tensioner T10020 clockwise until the stop and then tighten the nut -1- by hand.

Fig 12: Identifying Toothed Belt Removed From Coolant Pump And Remaining Pulleys

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

Installing

Camshaft is secured with the rig pin 3359.
Crankshaft is secured with crankshaft stop T10050 bzw. T10100.
Tensioning roller is secured with locking pin T10115 and seated on right stop.

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

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-- 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 14: Identifying Rear Toothed Belt Guard

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-- Loosen the nut of the tensioning roller and pull out the locking pin T10115.

-- Carefully turn the tensioning roller with the pin wrench T10020 in clockwise direction, until the indicator is located centrally in the gap -arrow- of the base plate.

Fig 15: Identifying Tensioning Roller Turned Using Pin Wrench T10020 In Clockwise Direction, Until Indicator Aligns In Gap Of Base Plate

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

-- Hold the tensioning roller in this position and tighten the nut on the tensioning roller as follows: to 20 Nm and 45° (1/8 turn) additional.

-- 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 pretensioned.

Fig 16: 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 T10050 bzw. T10100.

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

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

Fig 17: Identifying Rear Toothed Belt Cover Aligned With Marking On Camshaft Sensor Wheel

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-- Check if the crankshaft can be locked with the crankshaft stop T10050 bzw. T10100.

If the crankshaft cannot be locked:

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

Fig 18: Identifying Camshaft Pulley Bolts

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-- Lock the hub with the rig pin 3359.

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

Fig 19: Identifying Crankshaft Stop T10050

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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 20: 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 T10050 bzw. T10100.

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

-- Check again.

-- Mount the engine mount bracket on the cylinder block and tighten the mounting bolts -arrows- to 40 Nm + 180° (¹ /₂ turn) additional turn.

Fig 21: Identifying Engine Bracket 10-222A Bolts

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NOTE:

Before the engine mount can be installed, all bolts -arrows- for the engine mount bracket must be tightened to specification.

-- Install the engine mount/body (replace bolts) ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

-- Fasten the engine mount to the engine mount bracket ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS . To do so, bring contact surfaces into contact using engine support bridge 10 - 222A.

-- Install the lower and center toothed belt guard.

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

-- Install ribbed belt RIBBED DRIVE BELT .

-- Install upper toothed belt guard.

-- Install the connecting tubes for charge air cooler/turbocharger and charge air cooler/intake connection TURBOCHARGER ASSEMBLY OVERVIEW .

-- Install the right front wheel housing liner Removal and Installation .

-- Install the coolant expansion tank COOLING SYSTEM COMPONENTS ASSEMBLY OVERVIEW, BODY SIDE .