Removal and Replacement

Toothed belt, removing, installing and tensioning





Special tools, testers and auxiliary items required
^ Engine support bridge 10 - 222 A with bracket for engine 10 - 222 A/1
^ Retainer 3180
^ Tensioning bolt T10092
^ Securing pin T40011
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Locking fluid D 000 600 A2

Removing
- Read safety precautions before beginning work on fuel supply system.
- Observe Rules for Cleanliness.
- Remove engine cover.
- Remove sound insulation tray.
- Remove right headlamp.
- Remove air guide pipe between turbocharger and charge air cooler.
- Remove ribbed belt.
- Remove ribbed belt tensioning element.

Engine installed:





- Position crankshaft at TDC cylinder 1 (vehicles with manual transmission).





- Position crankshaft at TDC cylinder 1 (vehicles with automatic transmission).

With engine removed:





- Position vibration damper to TDC cylinder 1 - arrows-.
- Remove coolant expansion tank and set aside.
- Remove power steering fluid reservoir and set aside.
- Remove vacuum line to throttle valve connection.
- Remove upper toothed belt guard.





- Install engine support bridge 10 - 222 A with bracket for engine 10 - 222 A /1.
- Engage Retainer 3180 on right lifting eye and tighten on cylinder head and lightly pre-tension engine.





- Remove bolts from subframe/engine bracket, subframe/body and subframe brackets/body - arrows - and completely remove subframe.
- Remove engine bracket on cylinder block.





- Remove vibration damper/belt pulley.
- Remove lower and middle toothed belt cover.
- Mark direction of rotation of toothed belt.





- Install tensioning bolt T10092 into tensioning device for toothed belt.
- If necessary, align pressure piston before tensioning using needle nose pliers or a thin wire (hole in pressure piston and hole in housing must line up).
- Tension pressure piston of tensioner just enough that the pressure piston can be secured using Locking Pin T40011.
- Remove toothed belt.
- Turn crankshaft back slightly.

Installing

Note: When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.

A - Toothed belt completely removed
If toothed belt was only removed from camshaft gear

Conditions
^ The pistons must not be positioned at TDC.

Work procedure





- Align marking on camshaft gear with marking on cylinder head cover.
- Place toothed belt onto crankshaft sprocket (observe direction of rotation).
- Install engine bracket on cylinder block. Torque specification 45 Nm

Note: Before installing engine bracket, insert bolts in bracket.

- Install toothed belt cover - lower part. (Insert bolts with Locking Compound D 000 600 A2.) Torque specification: 10 Nm
- Using a bolt, secure vibration damper/belt pulley (watch locating point).





- Turn crankshaft to set cylinder 1 at TDC.
- Position toothed belt on coolant pump, tensioning roller and camshaft gear.
- Tension toothed belt.

B - Toothed belt only removed from camshaft gear





- Align marking on camshaft sprocket with marking on cylinder head cover.
- Turn crankshaft to set cylinder 1 at TDC.
- Place toothed belt on camshaft gear.
- Tension toothed belt

Toothed belt, tensioning





- Tension toothed belt. To do this, remove pin T40011 and remove tensioning bolt T1 0092.
- Turn over crankshaft twice and check if markings on camshaft and crankshaft still align with their reference points.
- Install vibration damper and belt pulley tightening torque: 25 Nm
- Install center part of toothed belt (insert bolts with Locking Compound D 000 600 A2.) Torque specification: 10 Nm
- Install toothed belt cover - upper part.
- Install engine mount.
- Install tensioner for ribbed belt. Torque specification: 25 Nm
- Install ribbed belt.