Withdrawal
Remove the right front wheel. Remove soundproof screen.
Instruction. Mark the direction of rotation of the V-ribbed belt with chalk or felt-tip pen. Reversing the running direction of a used belt can damage it.
To loosen the tension of the V-ribbed belt, use a ring wrench to tilt the tensioner in the direction -arrow-. Lock tensioner by inserting locking pin -T10060 A- or -T10060- into locking holes. Remove polyclinic crown.
Remove the engine hood. Remove engine cover -arrows-. Remove the noise shield below by disconnecting the crankcase ventilation hose.
Remove caps 3- and -4- from wiper arms with a screwdriver. Loosen nuts on both wiper arms a few turns. Release levers -1- and -2- by slightly deflecting them on the wiper shafts. Loosen nuts completely and remove wiper arms. Disconnect the washer fluid pipe -3-. Unplug electrical connectors -4- and -5- for heated washer nozzles. Unclip hose clamp -6- Using hose clamp pliers -VAG 1921-, remove drain hose from fairing grille. Shine the rubber seal -1- of the fairing grille. Remove fairing grille -2-. Release the washer fluid pipe.
Remove bolts and nuts -arrows-. Remove the fresh air intake duct and hang it over the right side of the vehicle.
Unplug electrical connector -2- from air mass meter -g70-. Detach vacuum hose -1-. Release hose clamp -4- and remove air duct with air mass meter -G70-. Pos. -3- ignore.
Remove air hose -2- connecting intercooler and intake manifold. Pos. -1- ignore.
Unscrew poly V-belt tensioner -arrow-.
Remove upper toothed belt cover by opening retaining clips -arrows-.
Loosen the damper while holding the center bolt with a spanner wrench.
Unscrew center and bottom toothed belt covers -arrows-.
Remove lower bolt -1- for engine mount. Bolts -2- and -3- will be removed later.
Screw front right load eyelet -T40016- to cylinder head.
Screw rear left load eye -t40016/1- to cylinder head.
Position crosshead -10-222 A- with adapters -10-222 A/13- on wing connecting edges. The lead screw of the traverse is facing forward.
Install 2 eyelets -10-222 A/12- on rear left load eye -T4001b- on cylinder head. Attach lifting device -2024 A- to engine and crosshead -10-222 A- as shown.
Instruction. To equalize the position of the center of gravity of the power unit, the hook bars must be inserted as shown in the figure. The hooks and locking pins of the hanging device must be secured with cotter pins.
Tighten the motor on the lead screw. Do not lift the engine. Loosen nut -3- only when replacing engine mounting.
Remove bolts -1- and -2- and remove bracket with engine mount. Remove bolts -2- and -3- and remove engine support.
Carefully! The engine may only be turned by the crankshaft in the direction of engine rotation (clockwise). To rotate the engine shaft, install the central bolt on the crankshaft.
Bring the crankshaft to the TDC position of the first cylinder. Arrow with the inscription "3Z" on the toothed belt rear cover must point to the toothed rim of the hub -arrows-. Secure camshaft hub with locking pin -3359-. Secure crankshaft gear with crankshaft stop -T10050-.
Instruction. The stopper should be installed on the toothed belt gear only from the front side of the toothed rim.
Markings on toothed belt sprocket and crankshaft stop -T10050- must be opposite each other. The pin of the crankshaft stop -T10050- must engage in the seal hole. flange.
Mark the direction of rotation of the toothed belt with chalk or felt-tip pen. Remove bolts -arrows- for camshaft gear.
Insert hexagon socket wrench into hexagon hole as far as it will go and turn tensioning pulley anti-clockwise -arrow- until tensioner is secured with locking plate -T10008-.
Instruction. To avoid damage, insert the Allen key as far as it will go. The tensioning element of the toothed belt is equipped with an oil stop, so it can only be squeezed gradually and with a uniform force.
Unscrew the fixing nut of the tension roller.
Remove bolts -arrows- and remove toothed belt tensioner. Remove toothed belt.
Installation (variable valve timing)
The camshaft is secured with pins -3359-. The crankshaft is secured with crankshaft stopper -T10050-. The tensioning pulley is secured with a locking plate -T10008-.
Instruction. Timing belt adjustment should only be done when the engine is cold. When turning the camshaft, one of the crankshaft pistons must not be at TDC. Risk of damage to valves/piston crowns.
Do not completely screw in bolts -arrow-. The camshaft gear must rotate and must not oscillate. Turn the camshaft gear in the grooves clockwise until it stops. Install the toothed belt on the camshaft gear, tensioner pulley, crankshaft gear and lastly on the coolant pump gear. Install the toothed belt tensioner. Adjust toothed belt tension as follows: turn eccentric counterclockwise with 2-hole wrench -3387- -arrow- to stop -A-. Remove locking plate -T10008-.
To protect against cuts, wrap the tip and cutting edges of the drill with 7 mm insulating tape. Slowly turn the key clockwise -arrow- until the 7.0 mm drill bit -pos. 2- will not pass freely between the lever and the tensioner housing. Distance -a- = 7.0±1.0 mm.
Instruction. Distance -a- decreases when tightening the tensioning roller nut, set it initially large. When the engine warms up, the distance -a- decreases.
Hold the tensioning roller in this position and tighten the tensioning roller nut to 20 Nm + 45°.
Tighten bolts -arrows- for camshaft gear to 25 Nm. Remove locking pin -3359- and crankshaft stop -T10050-.
Carefully! The engine may only be turned by the crankshaft in the direction of engine rotation (clockwise).
Rotate the crankshaft 2 revolutions in the direction of engine rotation until the crankshaft is almost at TDC. Make sure that the distance -a- between the lever and the tensioner housing is sufficient. Distance -a- = 7.0±1.0 mm. If distance -a- is not sufficient, adjust tensioning roller as follows: fix tensioning roller with 2-hole wrench -3387-, unscrew nut -1- and turn wrench -in direction of arrow- until distance -a- is sufficient. Distance -a- - 7.0±1.0 mm. Hold the tensioning roller in this position and tighten the tensioning roller nut to 20 Nm + 45°.
Valve timing control
To check, secure crankshaft gear with crankshaft stop -T10050-. Markings on toothed belt sprocket and crankshaft stop -T10050- must be opposite each other. The pin of the crankshaft stop -T10050- must engage in the seal hole. flange. During rotation, the pin of the crankshaft stop -T10050- must engage with the seal. flange.
Instruction. If the crankshaft has been turned past TDC, it must first be turned back 1/4 of a turn in order to then be reset to TDC in the direction of engine rotation. Correction against the direction of engine rotation for fitting the crankshaft stop -T10050- is not permitted.
Check that the camshaft hub can be locked using locking pin -3359-.
If the hub does not lock: Remove bolts -arrows- for camshaft gear. Install a ring wrench on the camshaft center bolt. Turn hub until locking pin -3359- can be inserted. Tighten bolts -arrows- for camshaft gear to 20 Nm and turn 45°further. Remove the locking pin and crankshaft stopper. Rotate the crankshaft 2 revolutions in the direction of engine rotation until the crankshaft is almost at TDC. Re-check distribution phases.
Installation
Installation is in reverse order, while it is necessary to install the lower and middle covers of the toothed belt. Install vibration damper. Install the engine mount bracket. Install the upper toothed belt cover. Install poly V-belt. Install and adjust wiper arms.
Instruction. The hoses and pipes of the air pressurization system must be cleaned of oils and grease before installation. Never use lubricants.
Tightening torques:
- Toothed belt tensioner to cylinder block: 15 Nm
- Camshaft gear to hub: 25 Nm
- Timing belt tensioner to cylinder head: 20 Nm + 45°
- Timing belt lower cover to cylinder block: 10 Nm 1)
- Middle toothed belt cover to cylinder block: 10 Nm 1)
- Engine support to cylinder block: 45 Nm
- V-ribbed belt tensioner to alternator bracket: 22 Nm
1) Before installation, lubricate the bolts with thread varnish
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