Removal and Replacement
Toothed belt, removing, installing and tensioning
Adjusting valve timing)
Special tools and equipment
^ 10-222 A Support device (Modifying guide 10222 A/1)
^ 10-222 A/8 Adapter
^ V.A.G. 1331 Torque wrench (5...50 Nm)
^ V.A.G. 1332 Torque wrench (40...200 Nm)
^ T10020 Two-hole pin wrench
Modifying guide 10-222A/21 from support device 10-222A
Support device 10-222A is required to support engine/transmission assembly.
A new hole is required on guide 10-222A/21 to secure adapter 10-222/A18.
Dimensions given are in mm.
^ Drill a 12.5 mm diameter hole (arrow) in guide 10-222A/21.
Removing
^ Remove engine cover.
^ Removing right-hand sound insulation tray:
^ Remove ribbed belt.
^ Remove tensioning element for ribbed belt.
^ Remove coolant expansion tank (coolant hoses remain connected).
^ Remove toothed belt guard - upper part.
^ Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft sprocket must align with arrow on toothed belt guard.
^ Install support 10-222A with legs 10-222A/8 as shown.
^ Remove securing bolts from assembly mounting engine mounting, assembly mounting/body and assembly mounting/body mounting (arrows) and remove assembly mounting complete.
^ Remove vibration damper/belt pulley.
^ Remove engine bracket from cylinder block.
Note: When loosening the front engine mounting bolt the engine must be raised slightly with the support bracket.
^ Remove toothed belt guard - center and lower parts.
^ Mark direction of rotation of toothed belt.
^ Release tensioner and take off toothed belt.
^ Turn crankshaft back slightly.
Installing
Requirements
^ The pistons must not be positioned at TDC.
Work sequence
^ Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation).
Note:
Engine removed:
Begin by installing lower section of toothed belt guard as well as belt pulley/vibration damper.
Adjusting valve timing
Note: When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
^ Bring mark on camshaft into line with mark on toothed belt guard.
Engine installed:
^ Turn crankshaft to TDC No. 1 cylinder (models with manual transmission).
^ Turn crankshaft to TDC No. 1 cylinder (models with automatic transmission).
Engine removed:
^ Position vibration damper at TDC No. 1 cylinder (arrows).
^ Place toothed belt on tensioning roller and camshaft pulley.
Tensioning toothed belt
Requirements
^ Engine must only be hand touch warm.
^ Camshaft sprocket is at TDC No. 1 cylinder.
^ Before tensioning toothed belt, turn tensioning roller on eccentric with a pin wrench T10020 five times fully onto the limit stops in both directions.
Work sequence
^ Tension toothed belt. Do this by turning eccentric to left (direction of arrow) with 2-hole pin wrench T10020 onto limit stop.
^ Then release tension on toothed belt until notch -1- and indicator-2 align (use mirror).
^ Tighten securing nut to 20 Nm.
^ Turn crankshaft two turns in engine direction of rotation until engine is again at TDC No. 1 cylinder. When doing this it is essential that last 45° (1/8 turn) is completed without stopping.
^ Check toothed belt tension again
Specification: Indicator and notch align
Continuation, install complete toothed belt
^ Install toothed belt guard - center and lower parts.
^ Install vibration damper/belt pulley and torque to 25 Nm.
^ Install engine mounting to cylinder block and torque to 45 Nm.
^ Install engine assembly mountings complete.
Note: Insert bolts into engine bracket before installing engine bracket.
^ Align assembly mountings for engine and transmission.
^ Remove engine support bracket 10-222 A.
^ Install toothed belt guard - upper part.
^ Install ribbed belt tensioning element and torque to 25 Nm
^ Install ribbed belt.
^ Install coolant expansion tank.
^ Install right-hand sound insulation tray:
^ Install engine cover.