Toothed Belt: Removing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The toothed belt may be adjusted only when the engine is cold because the position of the pointer on the tensioner will change due to the temperature of the engine.

CAUTION: A used toothed belt could be destroyed if the running direction is reversed.

Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for installation later.

-- Remove the engine cover. Refer to ENGINE COVER .

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

-- Remove the bolts -3- and the coolant reservoir -2-.

Fig 1: Identifying Coolant Reservoir, Bolts And Connector

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-- Disconnect and remove the connector for the coolant reservoir -2-.

-- Set the coolant reservoir -2- aside.

WARNING:

Very hot fuel can burn your skin.

The temperature of the fuel lines and may reach 100° C (212° F) after stopping the engine. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

-- Open the couplings -A- and -B- and remove the fuel lines. Disconnect the couplings. Refer to Description and Operation .

Fig 2: Identifying Fuel Line Couplers

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-- Remove the fuel filter and set it aside. Refer to Description and Operation .

-- Disconnect the connector -2-.

Fig 3: Disconnecting Connector On Exhaust Pressure Sensor 1 -G450

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-- Remove the screw -3- and then remove the Differential Pressure Sensor -G505- from the bracket -arrow-.

-- Remove the screw -1- at the top of the particulate filter mount.

-- Lay the Differential Pressure Sensor -G505- and mount on the particulate filter.

-- Open the clips -arrows- and remove the toothed belt guard.

Fig 4: Removing Upper Toothed Belt Guard

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-- Remove right front wheel housing liner. Refer to Removal and Installation .

-- Remove the ribbed belt. Refer to RIBBED BELT WITH TENSIONER AND A/C COMPRESSOR .

-- Remove the vibration damper. Refer to -item 29-.

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

Fig 5: Identifying Lower And Center Toothed Belt Guard Bolts

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-- Rotate the engine to TDC and secure the crankshaft toothed belt gear with the Crankshaft Stop T10050.

Fig 6: Identifying Crankshaft Toothed Belt Pulley And Crankshaft Stop T10050

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-- The crankshaft stop can be pushed from the front side of the toothed belt sprocket onto the crankshaft toothed belt gear splines -2-. The toothed segment must be at 12 o'clock.

NOTE: The markings on the crankshaft toothed belt sprocket -2- and the Crankshaft Stop T10050 -1- must align.

-- The pins for the Crankshaft Stop T10050 must attach in the openings -arrow - for the sealing flange.

Fig 7: Identifying Crankshaft Stop T10050

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-- Mark direction of rotation of toothed belt.

-- Loosen the camshaft sprocket bolts -1-.

Fig 8: Identifying Camshaft Pulley Securing Bolts

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-- Loosen the high pressure pump toothed belt sprocket bolts -2-.

Fig 9: Identifying Coolant Pipe Bolt And High Pressure Fuel Pump Toothed Belt Gear

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-- Loosen the tensioning roller nut -1-.

Fig 10: Identifying Long Reach T10264 And Locking Tool T10265

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-- Turn the tensioning roller eccentric pulley with the Socket T10264 counter-clockwise -arrow- until the tensioning roller can be locked with the Locking Pin T10265.

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

Fig 11: Identifying Long Reach T10264 And Locking Tool T10265

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-- Remove the toothed belt from the idler roller and then from the remaining toothed belt gears.