I: option before 12.07
II: option from 01.08
Cars until 12.07
Remove the engine bracket. Remove the timing belt. Remove the tension roller. Unscrew all the idler rollers from the engine. Remove the camshaft gear, including the hub, from the camshaft. Remove the coolant pump. Unscrew the upper fuel injection pump mounting bolt. Unscrew the "arrow" mounting bolt of the toothed belt protective cover above the fuel injection pump.
Unscrew the rear bolt securing the "arrow" of the toothed belt protective cover.
Carefully detach the timing belt protective cover from the valve cover "arrows".
Disconnect the connector of the Hall sensor "C40" "arrow". Remove the connector from its mount.
Unscrew the Hall sensor "C40" "arrow". Pull the toothed belt protective cover slightly upwards and fold it away from the engine. Remove the Hall sensor "G40".
Installation in reverse order. In this case, it is necessary to consider the following. Lay the toothed belt and adjust the valve timing. Check whether the valve cover and the toothed belt protective cover are properly connected. For proper installation, press with a screwdriver on the belt cover at the installation points of the "arrows" clamps in the direction of the valve cover. The clamps should snap into place with a distinct click. Check for a gap between the hub and the toothed belt protective cover.
Cars from 01.08
Remove the front right mudguard. Remove the poly V-belt. Remove the vibration damper. Set the crankshaft to the TDC position of the first cylinder and lock the toothed pulley of the crankshaft using the "T10050" lock. To do this, insert the crankshaft lock 8 teeth of the pulley from its end side. The toothed segment of the camshaft pulley should be facing upwards ("12 o'clock position").
Instructions: The marks on the toothed crankshaft pulley "2" and the crankshaft lock -T10050-1- must match. In this case, the rod of the crankshaft lock "T10050" must enter the hole of the sealing flange.
Loosen screws "1" securing the camshaft pulley.
Loosen screw "1" securing the cooling system tube, and then screws "2" securing the fuel injection pump pulley.
(The original information is posted on the website: VWMANUAL)
Loosen the tension roller fastening nut "1" and turn the tension roller eccentric with the socket wrench "T10264" counterclockwise "arrow" until the tension roller can be fixed with the lock "T10265".
Turn the tension roller eccentric clockwise "arrow" until it stops and tighten the fastening nut "1" by hand. Remove the toothed belt from the overrunning roller and the high-pressure fuel pump.
Disconnect the connector of the Hall sensor "C40" "arrow". Remove the connector from its mount.
Unscrew the Hall sensor "C40" "arrow".
Remove the spacer and the repair hole cover "arrow" with a screwdriver. Remove the Hall sensor "G40" from the cylinder head and insert its connector through the repair hole into the Protective cover of the toothed belt.
Installation in reverse order. The following must be taken into account. Close the repair hole in the toothed belt casing with a rubber plug. Install the toothed belt and adjust the valve timing.
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