Removing and installing toothed belt, 2010 ►: VW 2.0 (AXA)

Removing and installing toothed belt, 2010 ►
Special tools and workshop equipment required
Support bracket
10 - 222 A
Adapter
10 - 222 A /3
Adapter
10 - 222 A /16
Adapter
10 - 222 A /23
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
2-hole pin wrench
T10020
Removing
Note
Note safety precautions before starting installation work
Chapter
.
Observe rules for cleanliness
Chapter
.
If necessary, equip
adapter
10 - 222 A /23
with
adapter
10 - 222 A /23-1
.
Install plenum chamber bulkhead on left and right
General body repairs, exterior
Rep. gr.
50
Bulkhead; Assembly overview - plenum chamber bulkhead
.
Unbolt right cover and battery cover from lock carrier
General body repairs, exterior
Rep. gr.
63
Front bumper
.
Remove throttle valve control module/air mass meter connecting hose
Chapter
.
Remove poly V-belt
Chapter
.
Unbolt power-assisted steering vane pump from ancillaries bracket and put to one side; hoses remain connected:
Running gear, axles, steering
Rep. gr.
48
Vane pump
.
Remove poly V-belt tensioning element
Item
.
Remove upper toothed belt guard.
Set camshaft pulley to marking for TDC No. 1 cylinder by turning crankshaft. Marking on camshaft pulley must align with arrow on cylinder head cover
arrows
.
Unclip cover cap on suspension strut.
Bolt
support bracket
V.A.G 10-222A
to respective
adapter
10-222A/23
Position
support bracket
10 222 A
together with
adapter
10 - 222 A /23
and
adapter
10 - 222 A /23-1
as shown.
Attach engine to lifting eye on cylinder head, using
additional hook
10-222A/2
.
Remove securing bolts from assembly mounting to engine bracket and assembly mounting to body
arrows
and completely remove assembly mounting.
Note
The assembly mounting may only be removed if the engine is supported with
support bracket
V.A.G 10-222A
!
The engine bracket must be loosened only when the assembly mounting has been removed.
Unbolt engine bracket from cylinder block
arrows
and remove.
Remove vibration damper/belt pulley.
Remove centre and lower toothed belt guards.
Mark direction of rotation of toothed belt.
Loosen tensioning roller and remove toothed belt.
Turn crankshaft back slightly.
Installing
Prerequisites
The engine must be no more than warm to touch.
The pistons must not be positioned at TDC.
Before tensioning toothed belt, turn tensioning roller on eccentric to stop five times in both directions using 2-hole pin wrench
T10020
.
Note
When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns.
Align mark on camshaft toothed belt pulley with mark on cylinder head cover.
Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation).
Install lower and middle toothed belt guard and the vibration damper/belt pulley
Chapter
.
Set engine to TDC No. 1 cylinder.
Now fit toothed belt to tensioning roller and camshaft toothed belt pulley.
Before tensioning toothed belt, turn tensioning roller on eccentric to stop five times in both directions using
pin wrench
T10020
.
Tension toothed belt. To do this, turn
2-hole pin wrench
T10020
on eccentric to left in
direction of arrow
to stop.
Then reduce tension on toothed belt until notch
1
and indicator
2
align (use mirror).
Tighten securing nut.
Turn crankshaft 2 full revolutions in direction of rotation until engine is again at TDC No. 1 cylinder. It is important that the last 45° rotation (
1
/
8
turn) is performed without interruption.
Check toothed belt tension again. Specification: pointer and notch align.
Using securing bolts
arrows
, mount engine bracket on cylinder block and tighten securing bolts.
Note
Before installing assembly mounting, tighten all engine bracket bolts to specified torque.
Install assembly mounting between engine and body and tighten new securing bolts.
Fit engine assembly mounting to engine bracket by bringing contact surfaces together using
support bracket
V.A.G 10-222A
and tighten
Chapter
.
Install vane pump for power-assisted steering
Running gear, axles, steering
Rep. gr.
48
Hydraulic power-assisted steering
.
Install poly V-belt tensioning element.
Install poly V-belt
Chapter
.
Install upper toothed belt guard.
Install throttle valve control module/air mass meter connecting hose
Chapter
.
Install plenum chamber bulkhead on left and right
General body repairs, exterior
Rep. gr.
50
Bulkhead; Assembly overview - plenum chamber bulkhead
.
Install right cover and battery cover on lock carrier:
General body repairs, exterior
Rep. gr.
63
Bumper
.
Specified torques
Chapter
“
Assembly overview - assembly mountings
”
Chapter
“
Assembly overview - cylinder block (pulley end)
”
Chapter
“
Assembly overview - poly V-belt drive
”