Removal and Replacement
Toothed belts, removing, installing and tensioning
Engines: AEG, APK, AQY, AVH, AZG, BEJ, BER, BEV, BHP
Special tools and equipment
^ 10-222A Engine support bracket with legs 10222A/1
^ T10004 Two hole pin wrench
^ V.A.G. 1331 Torque wrench (5 to 50 Nm)
^ V.A.G. 1332 Torque wrench (40 to 200 Nm)
Removing
- Remove engine cover.
- Remove right side sound insulation.
- Remove poly V-belt.
- Remove tensioning element for poly V-belt.
- Remove coolant expansion tank (supply hose remains connected, close union for return supply hose).
- Remove power steering reservoir (hoses remain connected).
- Remove toothed belt guard upper part.
- Set camshaft pulley to TDC No. 1 cylinder by turning the crankshaft 1. Mark on camshaft pulley must align with (arrow) on toothed belt guard.
- Mount support 10-222A with legs 10-222A/1 as shown.
- Remove securing bolts from assembly mounting/engine bracket, assembly mounting/body and assembly mounting bracket/body (arrows) and remove assembly mounting complete.
- Remove vibration damper/belt pulley.
- Remove engine bracket from cylinder head.
Note: When loosening the front engine mounting bolt the engine must be raised slightly with the support device.
- 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
- Pistons must not be positioned at TDC.
Work sequence
- Place toothed belt on crankshaft pulley and coolant pump pulley (observe direction of rotation).
Note:
^ With engine removed:
^ Install lower toothed belt guard and vibration damper/belt pulley.
Adjust valve timing
Note:
^ When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.
- Align mark on camshaft with mark on toothed belt cover.
Engine installed:
- Turn crankshaft to TDC No. 1 cylinder (models with a manual transmission).
- Turn crankshaft to TDC No. 1 cylinder (models with an automatic transmission).
With engine removed:
- Position vibration damper at TDC No. 1 cylinder (arrows).
- Installed toothed belt on tensioning roller and camshaft pulley.
Tension toothed belt
Requirements
- The engine must be no more than warm to the touch.
- Camshaft pulley positioned at TDC for cylinder 1.
- Before tensioning toothed belt, turn tensioning roller 5 times on to limit stop (in both directions) at eccentric using pin wrench T10020.
Work sequence
- Tension toothed belt by turning eccentric to left (direction of arrow) with two hole pin wrench (T10020) onto limit stop.
- Release tension on toothed belt until notch -1- and indicator -2- align (use mirror).
- Tighten securing nut to 20 Nm.
- Turn crankshaft two rotations in engine direction of rotation and set again to DTC No. 1 cylinder. When doing this it is important that the last 45° (1/4 turn) is completed without interruptions.
- Check tension of toothed belt again.
Specification: Indicator and notch align.
Continue for completing installation of toothed belt
- Install center and lower toothed belt guard
- Install vibration damper/belt pulley.
Tightening torque: 25 Nm
- Install engine mounting to cylinder block.
Tightening torque: 45 Nm
- Install engine assembly mounting complete.
Note: Insert bolts into engine bracket before installing bracket
- Align assembly mountings for engine and transmission.
- Remove engine support device 10-222 A.
- Install toothed belt guard upper part.
- Install poly V-belt tensioning element.
Tightening torque: 25 Nm
- Install poly V-belt.
- Install coolant expansion tank.
- Install power steering reservoir.
- Install right side sound insulation:
- Check engine oil level and top off, if necessary.
- Install engine cover.