Removal and Replacement
Camshaft drive belt, removing, installing and tensioning
(Adjusting timing)
Special tools and equipment
^ Engine support bridge -10-222 A- (guide -10-222 A/21- changing)
^ Adapter -10-222 A/8-
^ Torque wrench -V.A.G. 1331-
^ Torque wrench -V.A.G. 1332-
^ Pin wrench -T10020-
Changing the Engine Support Bridge - 10-222 A- Guide - 10-222-A/21 -
- The engine support bridge -10-222 A- is needed to support the engine/transmission subassembly.
- A new bore is required for securing the adapter -10-222 A/8- to the guide
- A new bore is required to fasten 10-222 A/8 adapter to 10-222 A/21 guide.
- Drill one hole 12.5 mm diameter -arrow- in 10-222 A/21 guide.
Removing
- Remove right noise insulation cover.
- Remove engine cover.
- Remove ribbed belt
- Remove ribbed belt tensioning element.
- Remove the coolant expansion tank (the coolant hoses remain connected).
- Romove upper toothed belt guard.
- Bring camshaft gear to marking for TDC cyl.1 by turning crankshaft. Marking on camshaft gear must align with arrow on ribbed belt guard -arrows-.
- Mount the engine support bridge -10-222 A- with the feet -10-222 A/8 as illustrated.
- Remove the subframe -1- as follows:
- Remove the bolts -arrows-.
- Loosen the bolt -arrow A-.
Note:
^ The subframe may only be removed if the engine is supported by the engine support bridge - 10-222-A -
^ The engine branket must first be loosened only when the support frame is removed.
- Remove the Vibration damper/belt pulley.
- Remove the engine carrier from the cylinder block
Note:
^ To loosen the front engine mount bracket bolt, the engine be slightly lifted by the engine support bridge.
- Remove the center part and the lower part of the toothed belt guard.
- Mark direction of the rotation of the toothed belt.
- Loosen the tensioning roller and remove the toothed belt.
- Then, turn the crankshaft back slightly.
Installing
Conditions
^ The piston must not be at TDC; if necessary, turn the crankshaft slighly backward.
Procedure
- Mount the toothed belt on the crankshaft sprocket and the coolant pump (pay attention to the direction of rotation)
Note:
^With the engine removed beforehand, install the lower toothed belt guard as well as the vibration dampne/belt pulley.
Valve Timing, Adjusting
Note:
^ When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.
- Align the marking on the camshaft gear with the marking on the toothed belt guard -arrows-.
With Engine Installed
- Position crankshaft at TDC cylinder 1 (vehicles with manual transmission).
- Turn crankshaft to cyl. 1 TDC -arrow-. (vehicles with automatic transmission).
With Engine Removed:
- Turn vibration damper to cyl. 1 TDC -arrows-.
Continuation For Both
- Lay toothed belt on tensioner and camshaft gear.
Toothed Belt, Tensioning
Requirements
^ The Engine must be no more than warm to the touch.
^ Crankshaft is at TDC, cylinder 1.
^ 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
- Tension camshaft drive belt. Do this by turning eccentric to left (direction of arrow) with 2-hole pin wrench T 10020 onto stop.
- Release the toothed belt tension until the notch -1- and indicator -2- align. (Check using mirror).
- Tighten securing nut to 20 Nm (15 ft. lbs.)
- Continue turning crankshaft two turns in the direction of engine rotation until the engine is again at TDC cyl. 1. When doing this it is important that the last 45° (1/8 turn) turn is performed without stopping.
- Check the direction 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, torque securing bolts to 25 Nm (19 ft. lbs)
- Install engine bracket on cylinder block, torque securing bolts to 45 Nm (33 ft. lbs).
Note:
^ Before installing engine bracket, insert bolts in bracket.
^ Before the assembly mounting can be installed, all bolts for bracket must be tightened to 45 Nm (33 ft. lbs).
- Install subframe mount for engine for engine completely.
- Align subframe and transmission mounts.
- Remove engine support bridge -10-222 A-.
- Install toothed belt cover.
- Install ribbed belt tensioner. Tighten to 25 Nm (18 ft. lbs).
- Install ribbed belt.
- Install coolant expansion tank.
- Install engine cover.