Volkswagen Workshop Service and Repair Manuals

Removing and installing poly V-belt (vehicles with idler roller) Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-. Removing –  Remove noise insulation or underbody guard → General body repairs, exterior; Rep. gr.50. –  Loosen right wheel housing liner in front area. Polo

–  Unscrew bolts - 3, 4, 6- –  Push coolant lines -5- slightly to the side. l  To create space to remove bolt for idler roller/poly V-belt -2-. Continuation for all vehicles:

–  Unscrew bolt for poly V-belt idler roller -arrow- until poly V-belt can be removed easily. –  Remove poly V-belt. Installing –  Using a brush, coat guide surfaces of idler roller with lubricating paste. → Electronic parts catalogue (EKTA) G 052 751 A1.

–  Fit poly V-belt on poly V-belt pulley: 1 -  Vibration damper 2 -  Idler roller 3 -  Alternator 4 -  Air conditioner compressor –  Now insert idler roller, with its bolt, into guide of ancillary bracket.

Tightening sequence for poly V-belt idler roller. –  Tighten bolt in 5 stages.

Stage	Bolt	Specified torque/turning further angle
1.	-2-	screw in to stop by hand l  the poly V-belt is tensioned
2.	-2-	turn until tensioning roller bolt reaches stop l  the poly V-belt is tensioned further
3.	-2-	Turn back 90°
4.	-2-	30 Nm
5.	-2-	turn 90° further

l  Now check, as shown in illustration, whether the end of the bolt for idler roller/poly V-belt protrudes over the running surfaces of the idler roller. Dimension -a- = approx. 2.5 mm This ensures that the idler roller bolt was tightened up to its end position. Polo

–  Move coolant lines -5- back to installation positions, tighten -3, 4, 6-. 8 Nm. Continuation for all vehicles: –  Turn engine at least one turn in direction of rotation at the belt pulley/vibration damper central bolt.   Note t  Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioner compressor) are secured tightly. t  When fitting poly V-belt, check direction of belt rotation and ensure proper seating of belt in pulleys. After completing repair: –  Start engine and check belt running. –  If necessary, install front right wheel housing liner. –  Install noise insulation or skid plate → General body repairs, exterior; Rep. gr.50.