Removal
Toothed belt, removing(with engine installed)
- obtain radio security code
- disconnect battery ground strap
- battery is under rear seat
- remove coolant expansion tank cap
- remove sound insulation cover (arrows)
- drain coolant from radiator
- save for reuse, as necessary
- remove generator cooling air duct (left arrow)
- remove coolant hose
- disconnect outer half of air duct at generator (arrows)
- remove screws securing wiring at generator
Note: The generator wiring must be brought out at the side (not downward); otherwise, the generator air duct cannot be mounted.
- release tension on ribbed V-belt and remove belt in downward direction by placing 13 mm box wrench on hexagon guide of tensioner and pressing wrench slowly upwards (arrows)
- remove generator mounting bolts
- remove generator
- working from below, remove 3 bolts (arrows) for toothed belt guard (right side)
- torques: screws 1 and 2: 45 Nm (33 ft lb) screw 3: 25 Nm (18 ft lb)
- from inside engine compartment, remove bolts (lower arrow) securing bracket for air intake ducts on left and right
- remove intake ducts
- remove strut (upper arrows)
- torque: 20 Nm (15 ft lb)
- from inside engine compartment. remove bolts (arrows) securing upper part of air cleaner housing
- torque: 9 Nm (7 ft lb)
- remove bolts (arrows) securing lower part of air cleaner housing, press towards rear and lift out
- torque: 10 Nm (7 ft lb)
- remove upper radiator hose after loosening 3 hose clips (arrows) and after unclipping holder 1
- disconnect electric fan bolts (arrows) lift tan out and place to one side in engine compartment (wiring remains connected)
- torque; 10 Nm (7 ft lb)
- remove poly-ribbed belt
- remove belts (left 3 arrows) securing supporting clamp for lower radiator hose and take off upper part
- disconnect radiator hose at thermostat housing (right arrow)
- swing radiator hose to right at rear
- from inside engine compartment, remove fan shroud by unscrewing bolts (arrows) for viscous fan at top
- torque: 10 Nm (7 ft lb)
- disconnect and remove Idle Air Control Valve
- remove temperature sensor
- mounted over Idle Air Control Valve
- remove bolts securing viscous fan
Note: Use 2-hole nut wrench 3212 to hold.
Caution! Left-hand thread. turn to the right to loosen.
Note: For greater clarity the viscous fan is shown with the engine removed.
- take out viscous fan and fan shroud together by lifting upward
- disconnect engine support at front (arrows)
- torque: 40 Nm (30 ft lb)
Note: When re-installing engine. use shims of the same thickness to compensate engine support.
- remove radiator hose
- when reinstalling support, install radiator hose first
Note: Loosening/removing of vibration damper is only necessary if toothed belt is to be replaced, or if belt is removed for an engine related repair.
- loosen center nut of vibration damper by one turn (engine installed) using tool 2079 and holding tool 3197
- torque: 350 Nm (258 ft lb)
- torque: 450 Nm (332 ft lb) without 2079
Note: Picture shows use of 3197 and 2079 on a removed engine
- remove (left) toothed belt guard
- torque: 9 Nm (7 ft lb)
- remove lower part of supporting clamp for lower radiator hose (arrow).
- turn tensioner for ribbed belt in loosening direction and insert setting tool 3204 below mounting bolt (middle arrow in figure)
Note: Tensioner is shown with the engine removed.
- remove mounting bolts for right-hand toothed belt guard
- remove setting tool 3204
- remove mounting bolt at top
- torques: upper screw 10 Nm (7 ft lb) middle and lower screw 45 Nm (33 ft lb)
- remove toothed belt guard
- remove toothed belt guard toward top
- disconnect ignition cables (terminal 4) at ignition coils (arrow)
Caution! Right hand guard cannot be removed. Carefully lift guard from bottom to avoid damaging the radiator
- remove both ignition distributor caps
- turn engine to TDC
- marking on front of vibration damper
Note: If the bolt for the vibration damper has been loosened, use holding tool 3197 when turning crankshaft
- check that distributor rotor is pointing to marking on housing (arrow). if not, turn crankshaft one additional turn
- remove both distributors
- loosen stop plate A at toothed belt tensioner
- engine code PT
- loosen idler pulley C (with eccentric)
- disconnect toothed belt tensioner damper at B
- remove idler pulley C
^ for each cam; fit locating flange 3199 so that locating pin on distributor flange fits in slot on 3199
Note: If necessary, use hook wrench VW 544 to turn camshaft in both directions until the pins latch into the 3199 flange.
- secure flange 3199 tightly with distributor mounting bolts
Caution! Tool 3199 must not be used as holding tool to loosen camshaft bolt.
- loosen mounting bolts for camshaft sprockets approximately 2 turns (arrow)
- using a plastic hammer, tap edge of camshaft sprockets lightly loose
Caution! Woodruff keys must not be installed in camshaft sprocket/camshaft connection.
- remove four securing bolts for vibration damper
- remove center bolt for vibration damper and take out vibration damper with toothed belt sprocket
- Do not remove from crankshaft
Note: Mark rotation direction of toothed belt with crayon or felt pen. Reversing direction may cause engine damage. If vibration damper is tight, loosen center bolt a few turns only, unscrew two opposing bolts of the four bolts connecting vibration damper and toothed belt sprocket, and install puller 3198 in place of these.
- remove toothed belt