Drive Belts, Mounts, Brackets and Accessories: Service and Repair
Accessory Drive and Cylinder Block Overviews
• If large quantities of metal particles or abraded material are detected during engine repairs, it may mean the crankshaft or rod bearings are damaged. To prevent further damage, perform the following steps after the repair:
• Clean the oil passages.
• Replace the oil spray jets.
• Replace the oil cooler.
• Replace the oil filter.
I - Jetta from MY 05 through 07, with engine codes BGP and BGQ => [ Accessory Drive ]
II - Jetta from MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, with engine codes CBTA and CBUA => [ Accessory Drive ]
III - Jetta from MY 11 => [ Accessory Drive ]
IV - => [ Engine, Rear ]
V - Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10 => [ Engine, Front and Side ]
VI - Jetta from MY 11=> [ Engine, Front and Side ]
Accessory Drive
1 Bolt
• 25 Nm
2 Bolt
• 25 Nm
3 Generator
• Moving the threaded bushings in the generator slightly to the rear will make is easier to install the generator.
4 Bolt
• 25 Nm
5 Idler Pulley with Bracket
• For the ribbed belt for the Air Conditioning (A/C) compressor.
• Do not remove the pulley.
6 Bolt
• 25 Nm
7 A/C Compressor
8 Bolt
• 25 Nm
9 Coolant Pump
• In the cylinder block.
• Removing and installing, refer to => [ Coolant Pump ] Service and Repair.
10 Ribbed Belt, for the Generator and Coolant Pump
• Routing, refer to => [ Ribbed Belt Routing ].
• Before removing, mark the direction of rotation using chalk or a felt-tip marker.
When installing the old ribbed belt, make sure it is routed in the right direction and that it is seated correctly on the pulleys and the tensioner.
• Check for wear.
• Do not kink.
• Removing and installing, refer to => [ Ribbed Belt ] Ribbed Belt.
11 Ribbed Belt, for the A/C Compressor
• Routing, refer to => [ Ribbed Belt Routing ].
• Before removing, mark the direction of rotation using chalk or a felt-tip marker.
When installing the old ribbed belt, make sure it is routed in the right direction and that it is seated correctly on the pulleys and the tensioner.
• Check for wear.
• Do not kink.
• Removing and installing, refer to => [ Ribbed Belt ] Ribbed Belt.
12 Vibration Damper
• To remove and install, lock the crankshaft. Refer to => [ Crankshaft, Locking ] Procedures.
13 Bolt
• 50 Nm + 90° (1/4) additional turn.
• Always replace.
• Only use strength category 10.9.
• Quantity: 5
14 Bushing
• Quantity: 2
15 Belt Tensioner, for the A/C Compressor Ribbed Belt
• 35 Nm
• Do not remove the roller.
16 Belt Tensioner, for the Generator and Coolant Pump Ribbed Belt
• 35 Nm
• Do not remove the roller.
17 Bolt
• 25 Nm
18 Bolt
• 8 Nm
19 Upper Idler Pulley with Bracket
• For the generator and coolant pump ribbed belt.
• Do not remove the pulley.
20 Bolt
• 40 Nm + 90° (1/4) additional turn.
• Always replace.
21 Engine Mount
22 Bushing
• Quantity: 2
23 Accessory Bracket
Ribbed Belt Routing
1. Upper idler pulley
2. Pulley, generator
3. Lower idler pulley
4. Ribbed belt, for the generator and coolant pump
5. Pulley, for the A/C compressor
6. Ribbed belt, for the A/C compressor
7. Vibration damper
8. Belt tensioner, for the A/C compressor ribbed belt
9. Belt tensioner, for the generator and coolant pump ribbed belt
10. Pulley, coolant pump
Accessory Drive
1 Bolt
• 25 Nm
2 Bolt
• 25 Nm
3 Generator
• Moving the threaded bushings in the generator slightly to the rear will make is easier to install the generator.
4 Bolt
• 25 Nm
5 Idler Pulley wit Bracket
• For the Air Conditioning (A/C) compressor ribbed belt.
• Do not remove the pulley.
6 Bolt
• 25 Nm
7 A/C Compressor
8 Bolt
• 25 Nm
9 Coolant Pump
• In the cylinder block.
• Removing and installing, refer to => [ Coolant Pump ] Service and Repair.
10 Ribbed Belt, for the Generator and Coolant Pump
• Routing, refer to => [ Ribbed Belt Routing ].
• Before removing, mark the direction of rotation using chalk or a felt-tip marker.
When installing the old ribbed belt, make sure it is routed in the right direction and that it is seated correctly on the pulleys and the tensioner.
• Check for wear.
• Do not kink.
• Removing and installing, refer to => [ Ribbed Belt ] Ribbed Belt.
11 Ribbed Belt, for the A/C Compressor
• Routing, refer to => [ Ribbed Belt Routing ].
• Before removing, mark the direction of rotation using chalk or a felt-tip marker.
When installing the old ribbed belt, make sure it is routed in the right direction and that it is seated correctly on the pulleys and the tensioner.
• Check for wear.
• Do not kink.
• Removing and installing, refer to => [ Ribbed Belt ] Ribbed Belt.
12 Vibration Damper
• Multiple versions are available.
• To remove and install, lock the crankshaft => [ Crankshaft, Locking ] Procedures.
13 Bolt
• 50 Nm + 90° (1/4) additional turn.
• Always replace.
• Only use strength category 10.9.
• Quantity: 5
14 Bushing
• Quantity: 2
15 Belt Tensioner, for the A/C Compressor Ribbed Belt
• 35 Nm
• Do not remove the roller.
16 Belt Tensioner, for the Generator and Coolant Pump Ribbed Belt
• 35 Nm
• Do not remove the roller.
17 Bolt
• 25 Nm
18 Bolt
• 8 Nm
19 Upper Idler Pulley with Bracket
• For the generator and coolant pump ribbed belt.
• Do not remove the pulley.
20 Bolt
• 40 Nm + 90° (1/4) additional turn.
• Always replace.
21 Engine Mount
22 Bushing
• Quantity: 2
23 Accessory Bracket
Ribbed Belt Routing
1. Upper idler pulley
2. Pulley, generator
3. Lower idler pulley
4. Ribbed belt, for the generator and coolant pump
5. Pulley, A/C compressor
6. Ribbed belt, for the A/C compressor
7. Vibration damper
8. Belt tensioner, for the A/C compressor ribbed belt
9. Belt tensioner, for the generator and coolant pump ribbed belt
10. Pulley, coolant pump
Accessory Drive
1 Bolt
• 23 Nm
2 Pulley, for the Power Steering Pump
3 Bolt
• 23 Nm
4 Power Steering Pump
5 Accessory Bracket
6 Bolt
• 25 Nm
7 Bolt
• 25 Nm
8 Generator
• Moving the threaded bushings in the generator slightly to the rear will make is easier to install the generator.
9 Bolt
• 25 Nm
10 Lower Idler Pulley with Bracket
• For the Air Conditioning (A/C) compressor ribbed belt.
• Do not remove the pulley.
11 Bolt
• 25 Nm
12 Bushing
• Quantity: 2
13 A/C Compressor
14 Stud Bolt
• 25 Nm
• For attaching the power steering line.
15 Bolt
• 25 Nm
16 Ribbed Belt, for the Generator, Power Steering Pump and Coolant Pump
• Routing, refer to => [ Ribbed Belt Routing ].
• Before removing, mark the direction of rotation using chalk or a felt-tip marker.
When installing the old ribbed belt, make sure it is routed in the right direction and that it is seated correctly on the pulleys and the tensioner.
• Check for wear.
• Do not kink.
• Removing and installing, refer to => [ Ribbed Belt ] Ribbed Belt.
17 Ribbed Belt, for the A/C Compressor
• Routing, refer to => [ Ribbed Belt Routing ].
• Before removing, mark the direction of rotation using chalk or a felt-tip marker.
When installing the old ribbed belt, make sure it is routed in the right direction and that it is seated correctly on the pulleys and the tensioner.
• Check for wear.
• Do not kink.
• Removing and installing, refer to => [ Ribbed Belt ] Ribbed Belt.
18 Vibration Damper
• Multiple versions are available.
• To remove and install, lock the crankshaft, refer to => [ Crankshaft, Locking ] Procedures.
19 Bolt
• 50 Nm + 90° (1/4) additional turn.
• Always replace.
• Only use strength category 10.9.
• Quantity: 5
20 Coolant Pump
• In the cylinder block.
• Removing and installing, refer to => [ Coolant Pump ] Service and Repair.
21 Belt Tensioner, for the A/C Compressor Ribbed Belt
• 35 Nm
• Do not remove the roller.
22 Belt Tensioner for the Generator, Power Steering Pump and Coolant Pump
• 35 Nm
• Do not remove the roller.
23 Bolt
• 40 Nm + 90° (1/4) additional turn.
• Always replace.
24 Bolt
• 25 Nm
25 Bushing
• Quantity: 2
26 Engine Mount
Ribbed Belt Routing
1. Pulley, power steering pump
2. Ribbed belt, for the generator, power steering pump and coolant pump
3. Pulley, generator
4. Idler roller
5. Pulley, A/C compressor
6. Ribbed belt, for the A/C compressor
7. Vibration damper
8. Belt tensioner, for the A/C compressor ribbed belt
9. Belt tensioner, for the generator, power steering pump and coolant pump ribbed belt
10. Pulley, coolant pump
Engine, Rear
1 Cylinder Block
2 Locking Bolt
• 30 Nm
• With a rolled seal.
• The bore in the cylinder block is for locking the crankshaft using the locking pin (T40069).
3 Knock Sensor 1 (G61)
• Note the installed position: The wire connection points downward vertically.
4 Bolt
• 20 Nm
• Tightening specification affects the function of the knock sensor.
5 Bolt
• 10 Nm
6 Cover
7 Bayonet Connection
8 Wire Clip
• Clipped to the cover.
9 Knock Sensor 2 (G66)
• Note the installed position: The wire connection points 45° toward the right on the outside.
10 Wire Bracket
• Bolted to Secondary Air Injection (AIR) valve.
11 Connector
• Green for the knock sensor 1.
• Installed location, refer to => [ Installed Position of the Harness Connectors
for the Knock Sensors ].
• Contacts are gold plated.
12 Connector
• Gray for knock sensor 2.
• Installed location, refer to => [ Installed Position of the Harness Connectors
for the Knock Sensors ].
• Contacts are gold plated.
Installed Position of the Harness Connectors for the Knock Sensors
1. Green for the knock sensor 1
2. Gray for the knock sensor 2
Engine, Front and Side
1 Cylinder Block
2 Gasket
• Always replace.
3 Vacuum Pump, for the Brake Booster
• Do not open.
• Removing and installing, refer to => [ Brake Booster Vacuum Pump ] Brake Booster Vacuum Pump.
4 Bracket
5 Bolt
• 10 Nm
6 Oil Filter Bracket
• Overview, refer to => [ Oil Filter Bracket with Attachments Overview ] Service and Repair.
7 Bolt
• 25 Nm
8 Bolt
• 10 Nm
9 Bolt
• 10 Nm
10 Thermostat Housing
• With the thermostat and coolant pipe.
11 Bolt
• 10 Nm
12 Intake Manifold Support
• For engines with a Secondary Air Injection (AIR) system only.
13 Bolt
• 25 Nm
14 Bolt
• 10 Nm
15 Bolt
• 25 Nm
16 Accessory Bracket
17 Bolt
• 40 Nm + 90° (1/4) additional turn.
• Always replace.
18 Engine Mount
19 Guide Tube
• For the oil dipstick.
20 Transport Strap
• Not needed for service.
21 Bolt
• 25 Nm
22 Bolt
• 10 Nm
23 Coolant Pump
• With a integrated silicone seal for the cylinder block seal.
• Removing and installing, refer to => [ Coolant Pump ] Service and Repair.
Engine, Front and Side
1 Cylinder Block
2 Vacuum Pump, for the Brake Booster
• With the gasket.
• Replace the gasket.
• Do not open.
• Removing and installing, refer to => [ Brake Booster Vacuum Pump ] Brake Booster Vacuum Pump.
3 Bracket
4 Bolt
• 10 Nm
5 Reduced Oil Pressure Switch (F378)
• 20 Nm
6 Oil Pressure Switch (F1)
• 20 Nm
7 Oil Pressure Regulation Valve (N428)
8 Guide Tube
• For the oil dipstick.
9 Intake Manifold Support
• For engines with a Secondary Air Injection (AIR) system only.
10 Bolt
• 25 Nm
11 Pre-warmer
• Does not apply to the US/Canadian market.
12 Bolt
• 25 Nm
13 Bolt
• 10 Nm
14 Thermostat Housing
• With the thermostat and coolant pipe.
15 Bolt
• 25 Nm
16 Oil Filter Bracket
• Overview, refer to => [ Oil Filter Bracket with Attachments Overview ] Service and Repair.
17 Bolt
• 25 Nm
18 Accessory Bracket
19 Bolt
• 40 Nm + 90° (1/4) additional turn.
• Always replace.
20 Engine Mount
21 Bolt
• 25 Nm
22 Transport Strap
• Not needed for service.
23 Coolant Pump
• With a integrated silicone seal for the cylinder block seal.
• Removing and installing, refer to => [ Coolant Pump ] Service and Repair.
24 Bolt
• 10 Nm