Part I

NOTE:

From 08.00 a new tensioning roller and toothed belt gear are being installed for toothed belt drive. Tensioning roller must be adjusted in order to tension toothed belt.

Fig 1: Engine, Assembly Overview (Part I)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - 10 Nm

Replace

2 - Toothed belt cover - center part

3 - Toothed belt cover - upper part

4 - Toothed belt

Mark direction of rotation before removing
Check for wear
Do not kink
Removing and installing → Toothed belt, removing, installing and tensioning

5 - 65 Nm

Use retainer 3036 to loosen and tighten

6 - Camshaft sprocket

Note installed position: Thin rib of camshaft gear points outward and TDC marking cylinder 1 is visible

7 - 27 Nm

8 - Tensioning roller

up to 07.00: not adjustable

9 - Washer

10 - Tensioning roller

from 08.00: must be adjusted using a pin wrench 3387

11 - Washer

12 - 27 Nm

13 - Tensioner for toothed belt

up to 07.00: secure with pin T40011
from 08.00: secure with a plate T10008

14 - 25 Nm

15 - Idler roller

16 - 15 Nm

17 - O-ring

replace if damaged

18 - Coolant pump

Removing and installing → Coolant pump, removing and installing

19 - 15 Nm

20 - Crankshaft toothed belt sprocket

21 - 90 Nm plus ¹ / ₄ turn (90 ° )

Replace
The threads and shoulder must be free of oil and grease
Use counter-holder 3415 to loosen and tighten

22 - Toothed belt cover - lower part

23 - Pulley

for viscous fan clutch

24 - Ribbed belt

Mark direction of rotation before removing
Removing and installing → Ribbed belt, removing and installing

25 - Pulley

For power steering pump

26 - 25 Nm

27 - Belt pulley/harmonic balancer

for 2 belt drives
Only possible to install in one position - Bores are offset
Note position when installing toothed belt → Toothed belt, removing, installing and tensioning , Toothed belt, removing and installing, tensioning

28 - Ribbed belt tensioner

29 - Ribbed belt

For air conditioning compressor
Mark direction of rotation before removing
Removing and installing → Ribbed belt for air conditioning compressor, removing and installing

30 - Pulley

For air conditioning compressor
Securing A/C compressor - bracket - cylinder block → 87 - AIR CONDITIONING

31 - 10 Nm plus ¹ / ₄ turn (90 ° )

Replace

32 - Tensioner for ribbed belt

To release tension on ribbed belt, swing using open-end wrench → Ribbed belt, removing and installing

33 - 25 Nm

34 - Pulley

For generator