Withdrawal
Remove the right front wheel. Remove soundproofing. Remove poly V-belt. Remove the hood. If present, unfasten the bracket. Remove engine cover -arrows-. Remove the sound insulation underneath. Pry off caps -3 and 4- on both parts of wiper arm with a screwdriver. Loosen the nuts on both parts of the wiper arm with a few turns. Loosen windshield wiper arms -1 and 2- on axles one by one with light wiggles. Completely unscrew the nuts and remove both parts of the wiper arm. If it is not possible to remove the lever in this way, then in this case it is necessary to use a standard puller.
Disconnect washer fluid pipe -3-. If fitted, unplug electrical connectors -4 and 5- for heated windshield washer jets. Loosen hose clamp -6- using hose clamp pliers -VAG 1921- and remove drain hose from vent grille. Remove rubber seal -1- from deflector grille. Remove air vent grille -2-. Unfasten washer fluid supply pipe.
Remove nuts and bolts -arrows-. Pull the fresh air duct forward and remove it by turning it towards the right side of the vehicle.
Detach the air hose -1- from the suction pipe, to do this release the clips (where there are) -2- -arrow-.
Vehicles with letter designation AMF, VNS
Remove resonator from air pipe -arrow-.
All cars
Unplug electrical connector -2- for air mass meter -G70-. Remove vacuum hose -1-. Loosen hose clamp -4- and remove air pipe together with air mass meter -G70-. Pos. -3-disregard.
Unscrew tensioner for poly V-belt -arrows-. Remove top section of belt guard -arrows-.
Unscrew the vibration damper by holding the crankshaft with a spanner on the central bolt.
Unbolt center and bottom section of belt guard -arrows-.
Remove lower bolt -1- for engine mount. Bolts -2- and -3- are loosened later.
Position crosshead -10.222 A- with adapters -10.222 A/13- and adapter -T40093/6- on the edges of the wing bolt connections.
Carefully! In this case, insert adapter -10. 222 A/13- in the bonnet catches -arrow-.
Clamping screw in adapter -T40093/6- must be loosened. Install adapter -T40093/6- so that its bracket points upwards. Hook the hook of the lead screw carabiner -10.222 A/11- to the engine lug. Tighten the motor with the lead screw without lifting it.
Vehicles with cover for engine mounting
Remove the cover of the engine mounting, to do this unscrew the bolts -1 and 2-.
Loosen bolts -1 and 3- and remove bracket with engine mounting -2-.
Vehicles without engine mount cover
The nut -3- may only be loosened to replace the engine mount. Remove bolts -1 and 2- and remove bracket with engine mount.
All cars
Remove upper bolts -2- and -3- and remove engine support. Pos. -1- ignore.
Carefully! It is allowed to scroll the engine only by the crankshaft in the direction of its rotation (clockwise). To rotate the engine shaft, install the center bolt on the crankshaft.
Set crankshaft to mark "TDC". The gap between the two teeth of the camshaft sprocket must be opposite the marking 3Z on the rear of the belt guard -arrows-. Secure camshaft bushing with tool -3359-. Secure crankshaft sprocket with crankshaft stopper -T10050-.
Instruction. The crankshaft stop can only be pushed onto the sprocket teeth from the outside.
Markings for sprocket and crankshaft stop -T10050- must be opposite each other. The stud of the crankshaft stop -T10050- must engage in the seal bore. flange.
Mark the direction of rotation of the toothed belt with chalk or felt-tip pen. Loosen bolts -arrows- of camshaft sprockets.
Loosen securing nut -1- for tensioning roller. Turn the eccentric of the tensioning roller anti-clockwise -arrow- with the pin spanner -3387- until the tensioning roller can be secured using the locking pin -T10115-. The special tool Matra V/159 can be used instead of the pin spanner -3387-.
Turn pin wrench -3387- clockwise -arrow- as far as it will go and tighten securing nut -1- by hand. Remove the toothed belt first from the coolant pump and then from the remaining sprockets. Installation (valve timing adjustment). The camshaft is secured with the lock -3359-. The crankshaft is secured with crankshaft stopper -T10050-. The tensioning pulley is secured with the locking pin -T10115- and secured to the right stop with the fixing nut.
Instruction. Work on adjusting the toothed belt must always be carried out only when the engine is cold. When turning the camshafts, one of the crankshaft pistons must not be in "TDC". Risk of damage to valves/piston head.
Check that the tensioning pulley is seated correctly in the rear part of the belt guard -arrow-.
Screw in bolts -arrows- not completely. The camshaft sprocket should turn by hand, but not turn on its own. Turn the camshaft sprocket to the stop clockwise within its extended holes. Install the toothed belt on the camshaft sprocket, idler pulley, crankshaft sprocket and then on the coolant pump sprocket.
Set toothed belt tensioner as follows: Remove locking pin -T10115-. Loosen securing nut -1- for tensioning roller. Turn the eccentric of the tensioning roller clockwise -3387- clockwise with the pin spanner -arrow- until the pointer -2- is centered in front of the recess in the base plate.
Instruction. Make sure that the fixing nut does not turn.
Lock the tensioning roller in this position and tighten the tensioning roller nut to 20 Nm and 45°.
Instruction. When tightening the fixing nut, the pointer arrow rotates a maximum of 5 mm to the right out of the notch in the base plate. These provisions cannot be corrected, the so-called. After a while, the belt will stretch.
Position support wrench -T10172- with bolt -T10172/4- as shown in illustration and press -in direction of arrow- to pretension belt drive. Tighten bolts -1- for camshaft sprocket to 25 Nm. Remove retainer -3359- and crankshaft stop -T10050-.
Checking the valve timing
It is allowed to scroll the engine only by the crankshaft in the direction of its rotation (clockwise). Turn the crankshaft 2 turns in the direction of rotation so that it is again in front of the mark "TDC". Turn the bushing in the direction of engine rotation, lock it with locking pin -3359-. The gap between both teeth of the camshaft sprocket must be opposite the marking "3Z" rear section of belt guard -arrows-. For clarity, the camshaft sprocket is shown without the belt.
Check the following: that the crankshaft can be secured with the crankshaft stop -T10050-, that the pointer of the tensioning roller is in the middle or max. 5 mm to the right of the recess in the base plate. If the crankshaft cannot be fixed/loosen the fixing bolts -arrows-camshaft sprockets.
Turn crankshaft in direction of engine rotation until crankshaft stop -T10050- can be secured.
Instruction. If the crankshaft has crossed the mark "TDC", then first turn it back, then to re-set it to the mark "TDC" in the direction of rotation of the motor.
Tighten bolts -arrows- of camshaft sprocket to 25 Nm. Remove retainer -3359- and crankshaft stop -T10050-. It is allowed to scroll the engine only by the crankshaft in the direction of its rotation (clockwise).
Rotate the crankshaft 2 turns in the direction of engine rotation until it is back at the mark "TDC". Repeat the valve timing check.
Installation
It is carried out in the reverse order, while it is necessary that the hoses and the hose fitting of the air pressurization system must be cleaned of oils and grease before installation. Never use lubricants. Install the lower center part of the belt guard. Install vibration damper. Install bracket with engine mount. Install the upper part of the belt guard. Install the air ducts in the clamps. Install poly V-belt. Install the wiper arm.
Tightening torques:
- Camshaft sprocket to bushing: 25 Nm
- Timing belt tensioner to cylinder head: 20 Nm + 45°
- Lower part of the belt guard to the cylinder block: 10 Nm 1)
- Center section of belt guard to cylinder block: 10 Nm 1)
- Engine support to cylinder head: 45 Nm
- V-ribbed belt tensioner to accessory bracket: 22 Nm
- Engine compartment cover to bracket: 5.5 Nm
1) Use thread varnish to tighten bolts.
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