1. Lower the engine and connect it to the clutch housing.
2. Check that the flywheel mark corresponding to the installation of the piston of the first cylinder at TDC is aligned with the pointer. The fuel pump pulley and the camshaft are locked with the installation tools.
3. Loosen the camshaft pulley mounting bolt by half a turn, while using a wrench on the camshaft flats to hold the camshaft from turning. Remove the camshaft timing belt pulley from the camshaft mounting cone using a drift passed through the hole in the rear timing belt cover. Completely unscrew the pulley mounting bolt and remove the pulley.
4. Install the timing belt onto the crankshaft pulley, idler pulley, water pump pulley, fuel pump pulley and tensioner pulley.
Warning: When reinstalling the timing belt, install it so that the arrow on the belt, which was marked before removing the belt, matches the direction of rotation of the engine pulleys. If the timing belt rotates in the opposite direction after installation, cracks may occur in the belt and engine damage may occur.
5. Position the fuel pump pulley section in the middle position in the elongated hole and tighten the 3 pulley section mounting bolts to 20 Nm.
6. Install the camshaft timing belt pulley together with the timing belt and tighten the pulley mounting bolt by hand.
TDI diesel engine
7. Using a wrench (for example HAZET 2587), turn the timing belt tensioner clockwise until the marks on the tension roller and the tensioner hub (arrows) are aligned.
SDI diesel engine
8. Using an Allen key, turn the timing belt tensioner roller clockwise until the pointer aligns with the center of the setting tab.
9. Tighten the tension roller clamping nut to 25 Nm.
10. Check the installation position of the tension roller. The locking tab must be in the recess in the cylinder head. Otherwise, turn the tension roller holder in the appropriate direction.
11. Check that the flywheel timing mark is aligned with the pointer.
12. Tighten the camshaft pulley mounting bolt to a torque of 45 Nm, while using a wrench on the camshaft flats to prevent the camshaft from turning.
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13. Remove the high pressure fuel pump locking pin.
14. Remove the camshaft locking tool.
15. Rotate the engine crankshaft two full revolutions in the normal direction of rotation and re-set the piston of the first cylinder to TDC in the compression stroke. Check that the locking pin can be installed in the installation hole of the high-pressure fuel pump pulley. Check and, if necessary, readjust the tension of the toothed belt.
16. Check that the tension roller pointer is aligned with the installation mark. In this position, tighten the tension roller mounting nut to 20 Nm.
17. Replace and bolt the lower timing belt cover.
18. Install the crankshaft pulley and secure it with the bolts, tightening them to a torque of 25 Nm. Keep in mind that the pulley can only be installed in one position.
19. Install the upper timing belt cover.
20. Install the cylinder head cover.
21. Install and bolt the brake booster vacuum pump to the cylinder head.
SDI diesel engine
22. Install the intake manifold.
23. Tighten the bolts securing the right powertrain support to the engine to a torque of 45 Nm.
24. Using new bolts, secure the bracket to the right support and body and tighten the bolts to the specified torque:
- support to the body: 40 Nm + turn further by 90°;
- engine support: 60 Nm + turn further by 90°.
25. Remove the engine support fixture.
26. Install the V-belt tensioner element and secure it with the bolt, tightening it to a torque of 25 Nm.
27. Install the poly V-belt.
28. Install the lower engine splash shield.
29. Reinstall the expansion tank and power steering fluid reservoir.
TDI diesel engine
30. Install the pipe connecting the charge air radiator and the intake manifold.
31. Install the right headlight.
32. Check the injection timing of the high pressure fuel pump.
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