Removal and Installation
Toothed Belt
t / Engine support bridge -10-222A- ( guide -10-222A/21- changing Guide -10-222A/21-)
t / Adapter -10-222A/8-
t / Torque wrench -V.A.G1331-
t / Torque wrench -V.A.G1332-
t / Pin wrench -T10020-
Changing the Engine Support Bridge -10-222A- Guide -10-222A/21-
The engine support bridge -10-222A- is needed to support the engine/transmission subassembly.
A new bore is required for securing the adapter -10-222A/8- to the guide -10-222A/21- .
Dimensions in mm.
– / Drill a 12.5 mm diameter hole -arrow-into the guide -10-222A/21- .
Removing
– / Remove the right noise insulation Body Exterior:Description and Operation-50
– / Remove engine cover.
– / Remove ribbed belt Ribbed Belt.
– / Remove the ribbed belt tensioning element.
– / Remove the coolant expansion tank (the coolant hoses remain connected).
– / Remove upper toothed belt guard.
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– / Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard -arrows-.
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– / Mount the engine support bridge -10-222A- with the feet -10-222A/8- as illustrated.
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– / Remove the subframe -1-as follows:
– / Remove the bolts -arrows-.
– / Loose the bolt -arrowA-.
t / The subframe may only be removed if the engine is supported by the engine support bridge -10-222A- !
t / The engine bracket may first be loosened only when the subframe is removed.
– / Remove vibration damper/belt pulley.
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– / Remove the engine carrier from the cylinder block.
To loosen the front engine mount bracket bolt, the engine must be slightly lifted by the engine support bridge.
– / Remove the center part and the lower part of the toothed belt guard.
– / Mark direction of rotation of toothed belt.
– / Loosen the tensioning roller and remove the toothed belt.
– / Then, turn the crankshaft back slightly.
Installing
Conditions
l / The piston must not be at TDC; if necessary, turn the crankshaft slightly backward.
Procedure
– / Mount the toothed belt on the crankshaft sprocket and the coolant pump (pay attention to the direction of rotation).
With the engine removed beforehand, install the lower toothed belt guard as well as the vibration damper/belt pulley.
Valve Timing, Adjusting
When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.
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– / Align the marking on the camshaft gear with the marking on the toothed belt guard -arrows-.
With Engine Installed
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– / Position crankshaft at TDC cylinder 1 (vehicles with manual transmission).
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– / Position crankshaft at TDC cylinder 1 (vehicles with automatic transmission).
With Engine Removed
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– / Position vibration damper at TDC cylinder 1 -arrows-.
Continuation for Both
– / Lay toothed belt on tensioner and camshaft gear.
Toothed Belt, Tensioning
Requirements
l / The engine must be no more than warm to touch.
l / Crankshaft is at TDC, cylinder 1.
l / Before tensioning the toothed belt, turn the tensioning roller eccentric pulley using the pin wrench -T10020- five times all the way in both directions.
Procedure
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– / Tension toothed belt. To do this, turn the pin wrench -T10020- on the eccentric pulley to the left (direction of arrow) all the way.
– / Release the toothed belt tension until the notch -1-and the arrow -2-align (use a mirror).
– / Tighten mounting nuts to 20 Nm.
– / Continue turning the crankshaft two turns in the direction of the engine until the engine is once again at TDC for cylinder 1. For this it is necessary that the last 45 degrees ( 1/ 8rotation) is turned without interruption.
– / Check the tension on the toothed belt one more time, specified value: arrow and notch are aligned
Continuation, Installing the Complete Toothed Belt
– / Install center and lower part of the toothed belt cover.
– / Install the vibration damper/belt pulley.
Tightening specification: 25 Nm
– / Install engine bracket on cylinder block.
Tightening specification: 45 Nm
t / Before installing engine bracket, insert bolts in bracket.
t / Before the assembly mounting can be installed, all bolts for the engine bracket must be tightened to the tightening specification.
– / Install subframe mount for engine completely.
– / Align engine and transmission mounts Engine and Transmission Mount, Alignment Specifications.
Subframe tightening specifications: Engine and Transmission Mount Tightening Specifications.
– / Remove engine support bridge -10-222A- .
– / Install toothed belt cover - upper part.
– / Install the ribbed belt tensioning element.
Tightening specification: 25 Nm
– / Install ribbed belt Ribbed Belt.
– / Install coolant expansion tank.
– / Install the right noise insulation Body Exterior:Description and Operation-50
– / Install the engine cover.
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Portions of materials contained herein have been reprinted under license from Volkswagen Group of America, Inc., License Agreement 09507VWA.
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