Removal and Replacement

Toothed belts, removing, installing and tensioning






Special tools and equipment

- 10-222A Engine support bracket with legs 10222A11
- 3180 Retainer (for turbocharged engines)
- T10092 Tensioning bolt
- T40011 Locking pin
- VAG 1331 Torque wrench (5 to 50 Nm)
- VAG 1332 Torque wrench (40 to 200 Nm)
- D 000 600 A2 Locking fluid

Removing

- Note safety precautions before starting work.
- Observe rules for cleanliness.
- Remove engine cover.
- Remove insulation tray, refer to Body and Frame - Sound Proofing/Insulation - Service and Repair - Procedures Service and Repair
- Remove right-hand headlight, refer to Lighting and Horns - Headlamp - Service and Repair - Procedures Service and Repair
- Remove intake pipe between turbocharger and charge air cooler, refer to Powertrain Management - Fuel Delivery and Air Induction - Turbocharger - Service and Repair - Procedures Service and Repair
- Remove ribbed belt, refer to Engine - Drive Belts, Mounts, Brackets and Accessories - Drive Belt - Service and Repair - Procedures [1][2]Procedures
- Remove tensioning element for ribbed belt.

Engine installed:






- Turn crankshaft to TDC No. 1 cylinder (vehicles with manual transmission).






- Turn crankshaft to TDC No. 1 cylinder (vehicles with automatic transmission).

Engine removed:






- Turn vibration damper to TDC No. 1 cylinder-arrows-.
- Remove coolant expansion tank and place to side.
- Remove power assisted steering reservoir and place to side.
- Pull off vacuum pipes at activated charcoal filter and at throttle valve housing.
- Remove toothed belt guard-upper part.






- Install engine support bracket 10222A with legs 10-222A/1.
- Locate bracket 3180 in lifting eye on cylinder head and take-up weight of engine.






- Remove securing bolts from assembly mount/engine mount, assembly mount/body and assembly mount/body mount-arrows-and remove assembly mount complete.
- Remove engine mount on cylinder block.






- Remove vibration damper/belt pulley.
- Remove lower and center toothed belt guard.
- Mark direction of rotation of toothed belt.






- Screw tensioning bolt T10092 into toothed belt tensioning element.
- Align pressure piston using pointed pliers or wire before tensioning (hole in pressure piston must align with hole in housing).
- Tension piston of tensioning element just enough that the piston can be locked with locking pin T40011.
- Remove toothed belt.
- Turn crankshaft back slightly.

Installing

Note: When turning the camshaft crankshaft must not be at TDC. Danger of damage valves/piston crown.

A - Toothed belt completely removed
If toothed belt has only been removed from camshaft, skip down to B - Toothed belt only taken off camshaft sprocket

Conditions
The pistons must not be positioned at TDC.

Work sequence





- Bring mark on camshaft in line with the mark on cylinder head cover.
- Place toothed belt on crankshaft sprocket (observe direction of rotation).
- Install engine mount to cylinder block. Tightening torque: 45 Nm

Note: Before installing engine mount insert bolts into mount.

- Install lower part of toothed belt guard. (Insert securing bolts with locking fluid "D 000 600 A2".) Tightening torque: 10 Nm
- Secure vibration damper/belt pulley with one bolt (note arrangement).






- Turn crankshaft to TDC No. 1 cylinder.
- Install toothed belt onto coolant pump, tensioning roller and camshaft sprocket.
- Tension toothed belt

B-Toothed belt only taken off camshaft sprocket






- Bring mark on camshaft in line with the mark on cylinder head cover.
- Turn crankshaft to TDC No. 1 cylinder.
- Install toothed belt onto camshaft sprocket.
- Tension toothed belt.

Tensioning toothed belt






- Tension toothed belt by pulling out locking pin T40011 and removing tensioning bolt T10092.
- Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference points.
- Install vibration damper/belt pulley tightening torque: 25 Nm
- Install center part of toothed belt guard. (Insert securing bolts with locking fluid "D 000 600 A2".) Tightening torque: 10 Nm
- Install upper toothed belt guard.
- Install engine assembly mount, refer to Engine - Drive Belts, Mounts, Brackets and Accessories - Engine Mount - Service and Repair - Procedures Service and Repair
- Install ribbed belt tensioner. Tightening torque: 25 Nm
- Install ribbed belt, refer to Engine - Drive Belts, Mounts, Brackets and Accessories - Drive Belt - Service and Repair - Procedures [1][2]Procedures