Toothed Belt, Without 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 at the engine mount bracket area. Toothed belt, vehicles with divided toothed belt guard, removing and installing. Refer to TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

Special Tools And Workshop Equipment Required

Engine support bracket T 10339
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

NOTE:

In order to be able to remove the engine bracket, engine must be lifted quite far using engine support bridge 10-222A. To prevent damage to drive axles from significant bend angles, it is necessary to remove drive axles from transmission.

Removing

-- Remove engine cover/air filter 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 carefully 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 for the lines -1 through 3- and disconnect the hoses.

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.

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

-- Disconnect the line to the coolant pipe -arrow-. Collect 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 edges. Support the engine in the installed location.

CAUTION:

Ensure fender edges are not damaged.

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

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

Fig 7: Identifying Right Front Part Of Wheel Housing Liners

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

Fig 8: Identifying Camshaft Gear Moved To Marking For TDC Cylinder 1

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-- Remove the vibration damper pulley bolts and pulley.

Fig 9: Identifying Removal/Installation Vibration Damper/Belt Pulley

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-- Remove the lower section of the toothed belt guard bolts -arrows-.

Fig 10: Identifying Bolts From Lower Section Of Toothed Belt Guard

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

Fig 11: Identifying Engine Bracket Bolt

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NOTE:

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

-- Remove the front pipe with catalytic converter. Refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .

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

Fig 12: Identifying Pendulum Support & Bolts

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-- Remove the drive axles from transmission. Refer to Removal and Installation .

Fig 13: Identifying A/C System Pipes From Body

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-- Disconnect the Air Conditioning (A/C) lines from the body -arrows-.

NOTE:

Do not open the A/C system.

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

Fig 14: Identifying Subframe Mount/Engine Bracket Bolts

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CAUTION:

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

-- Lift the engine using the 10-222A far enough until both upper bolts -1 and 2- for the engine mount bracket can be loosened and removed.

Fig 15: Identifying Engine Bracket Bolt

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-- Continue to raise the engine until the engine bracket can be removed upward.

-- Remove the remaining toothed belt guard bolts -arrows- and remove the toothed belt guard from engine.

Fig 16: Identifying Remaining Bolts From Toothed Belt Guard

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-- 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.

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

-- Secure the lower toothed belt guard with the two lower bolts.

-- 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

-- Set the crankshaft and camshaft to TDC at cylinder 1 -arrows-.

Fig 17: Identifying Camshaft Gear Moved To Marking For TDC Cylinder 1

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

Fig 18: 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 19: 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 notch is above the tab (toothed belt excessively tensioned).

Fig 20: Identifying Tensioning Of Toothed Belt

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-- Release the tension on the toothed belt again.

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

-- Tighten the semi automatic tensioner roller nut.

Tightening specification: 25 Nm

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

-- Check the tension of the toothed belt again.

Specified value: Tab and notch align.

-- Check the TDC markings -arrows- again.

Fig 21: Identifying Camshaft Gear Moved To Marking For TDC Cylinder 1

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If the markings do not match:

-- Repeat the valve timing adjustment.

If the markings match:

-- Install toothed belt guard and bolts -1-.

Fig 22: Installing Toothed Belt Guard And Tighten Bolts

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-- Install the bolt -2- using locking compound AMV 185 101 A1 and tighten.

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

NOTE:

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

Fig 23: Identifying Engine Bracket Bolt

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-- Lower the engine using the 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. Tightening specification, refer to FASTENER TIGHTENING SPECIFICATIONS .

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

Fig 24: 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 25: Identifying Cover With Fuel Pump Control Module J538

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