Removal and Replacement

Camshaft drive belt, removing, installing and tensioning
(Adjusting timing)





Special tools and equipment
^ Engine support bridge -10-222 A- with feet 10-222 A/1-
^ Toothed belt tensioner -T-10200-
^ Torque wrench -V.A.G. 1331-
^ Torque wrench -V.A.G. 1332-



Removing
- Remove engine cover.
- Remove ribbed belt
- Remove ribbed belt tensioning element.
- Remove the coolant expansion tank (the coolant hoses remain connected).
- Remove the power steering fluid reservoir (the hoses stay connected).
- Romove upper part of 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 engine bracket -10-222-A/1 as shown.






- Unfasten bolts from subframe/engine bracket, subframe/body and subframe.


- 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.

Procedure

- Place the toothed belt onto the crankshaft sprocket and coolant pump (observe the direction of rotation)

Note:
^ With the engine removed beforehand: First install the lower part of the 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 tension of toothed belt again.
- Specified value: The alignment tab and alignment notch match up with each other.

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.


- Align subframe and transmission mounts.
- Tighten subframe mounts. Adjustments
- 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 the right insulation pan.
- Install engine cover.