Toothed Belt, Removing And Installing

Special tools and workshop equipment required

Engine Support Bridge 10-222A
Engine Support Bridge - Spindle 10-222A/11
Engine Support Bridge - Engine Support 2810-222A/28
Engine Support Bridge - Engine Support 3110-222A/31
Rail with Holes T40091/2 from the Engine Support - Basic Set T40091
Mount T40093/5 from the Engine Support - Supplement Kit T40093A
Engine Support Bridge - Engine Support 28-210-222A/28-2, quantity: 2
Square Pipe T40091/1 (quantity 2) from the Engine Support - Basic Set T40091
Movable Joint T40091/3 (quantity 2) from the Engine Support - Basic Set T40091
Movable Joint T40093/4 (quantity 2) from the Engine Support - Supplement Kit T40091
Torque Wrench 1331 5-50Nm VAG1331
Toothed Belt Tensioner T10020

Removing

-- Remove the noise insulation, refer to Removal And Installation .

-- Remove the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Remove the ribbed belt tensioning damper.

-- Remove the coolant reservoir. The coolant hoses remain connected.

-- Remove the upper toothed belt guard.

-- Turn the crankshaft in direction of engine rotation and move the camshaft sprocket to Top Dead Center (TDC) cylinder 1.

Fig 1: Turning Crankshaft In Direction Of Engine Rotation And Moving Camshaft Sprocket To Top Dead Center (TDC) Cylinder 1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The marking on camshaft sprocket must line up with the arrow on toothed belt guard -arrows-.

-- Hold the engine in its installed position, refer to ENGINE, SUPPORTING IN INSTALLED POSITION

-- Remove the engine mount bolts -arrows-.

Fig 2: Identifying Securing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine mount.

-- Remove the belt pulley/vibration damper.

Fig 3: Identifying Removal/Installation Of Vibration Damper/Belt Pulley

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine support from the cylinder block.

Fig 4: Identifying Engine Bracket-To-Cylinder Head Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

To loosen the front engine carrier bolt, the engine must be slightly lifted by the engine support bridge.

-- Remove the lower and center toothed belt guards.

-- Mark direction of rotation of toothed belt.

-- Loosen the tensioning roller and remove the toothed belt.

-- Then turn the crankshaft slightly backward.

Installing

Requirements

CAUTION:

Danger of causing damage to the pistons and the valves.

When turning camshaft, pistons may not be at TDC for any cylinder.

The engine must be no more than warm to touch.

-- Route the toothed belt over toothed belt sprocket for the crankshaft and coolant pump. Pay attention to the rotation direction of the toothed belt.

NOTE:

With the engine removed beforehand, install the toothed belt guard lower section as well as the vibration damper/belt pulley.

-- Align marking on camshaft sprocket with marking on the toothed belt guard.

Fig 5: Aligning Mark On Camshaft With Mark On Toothed Belt Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Engine Is Installed

-- Turn the crankshaft in direction of engine rotation to the upper TDC cylinder 1.

Vehicles with a manual transmission

Fig 6: Identifying Crankshaft At TDC No. 1 Cylinder (Vehicles With A Manual Transmission)
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Vehicles with an automatic transmission

Fig 7: Identifying Crankshaft At TDC No. 1 Cylinder (Automatic Transmission)
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Engine Removed

Fig 8: Identifying Cylinder 1 At TDC

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Set the belt pulley/vibration damper in direction of engine rotation to the top cylinder 1 dead center position -arrows-.

Continuation for All

-- Lay toothed belt on tensioner and camshaft gear.

-- Turn the tensioning roller at the eccentric pulley five times all the way in both directions using the Toothed Belt Tensioner T10020.

-- Tension the toothed belt. To do so, turn the Toothed Belt TensionerT10020 on the eccentric pulley all the way to the left in direction of -arrow-.

Fig 9: Releasing Tension On Toothed Belt Until Notch And Indicator Align (Engine Codes AEG, AVH, AZG, BEV)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Then release the tension on the toothed belt until the notch -1- and the pointer -2- are opposite each other. Use a mirror.

-- Tighten the nut.

Tightening specification: 20 Nm

-- Turn crankshaft over twice in engine running direction and then set cyl. 1 to TDC again.

For this it is necessary that the last 45° (¹ /₈ rotation) is turned without interruption.

-- Check tension of the toothed belt again.

Specified value: the pointer and the notch must be opposite each other.

If the tension on the ribbed belt is OK:

-- Install the lower and center toothed belt guards.

-- Install the belt pulley/vibration damper.

Tightening specification: 25 Nm

-- Attach the engine support to the cylinder block.

Tightening specification: 45 Nm

NOTE:

Install the bolts into the engine support before installing it.

-- Install the engine mount.

-- Align engine and transmission mountings SUBFRAME MOUNT, ADJUSTING .

NOTE:

For the subframe mount tightening specifications, refer to OVERVIEW - SUBFRAME MOUNT .

-- Remove the Engine Support Bridge 10-222A.

-- Install the upper toothed belt guard.

-- Install the ribbed belt tensioning element.

Tightening specification: 23 Nm

-- Install the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

The further installation is performed in reverse order of removal.