Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 10-222A Support bracket
• ◆ 10-222A/1 Support for support bracket
• ◆ T 10028 Counter-hold
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)

Checking main drive tensioning roller:

Test sequence

• ‒ → Remove cover above camshaft housing -arrows-.
• ‒ Remove air cleaner:

=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner

• ‒ Remove the toothed belt guard upper part.

The engine must be lowered slightly as follows to enable the crankshaft sprocket to be removed:

• ‒ → Fit support 10-222A with legs 10-222A/1 as shown.
• ‒ Remove power assisted steering reservoir and place to side.
• ‒ Remove air inlet to air cleaner.
• ‒ Remove upper securing bolt from lower toothed belt guard under console.

• ‒ Take-up weight of engine, and remove console as follows:

• ‒ → Remove securing bolts A, B and C
  and remove complete assembly mounting.
• ‒ Remove console from cylinder head.
• ‒ Lower engine until the pulley securing bolt is accessible.
• ‒ Mark the direction of rotation of the ribbed belt and remove belt as follows.

• ‒ → Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
• ‒ Remove ribbed belt.
• ‒ Remove engine bracket on cylinder head.

• ‒ → Now loosen the securing bolt for the pulley/toothed belt sprocket. To do this hold the pulley with counter-hold tool T10028.
• ‒ Remove pulley. Refit securing bolt with several washers to secure toothed belt sprocket.
• ‒ Now turn the crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1 cylinder.

• ‒ → Note the position of the tensioning roller indicator -arrow-. Press the toothed belt with firm thumb pressure. The indicator must move.
• ‒ Release tension on toothed belt.
• ‒ Turn crankshaft two turns in engine direction of rotation.
• ‒ Then check the position of the indicator. It must have returned to its original position.

If tensioning roller does not return to initial position:

• ‒ Replace tensioning roller.

Checking coupling drive tensioning roller:

• ‒ → Note the position of the tensioning roller indicator -1-. Press the toothed belt with firm thumb pressure -arrow-. The indicator must move.
• ‒ Release tension on toothed belt.
• ‒ Turn crankshaft two turns in engine direction of rotation.

• ‒ Then check the position of the indicator. It must have returned to its original position.

If tensioning roller does not return to initial position:

• ‒ Replace tensioning roller.

If both tensioning rollers are OK:

• ‒ Refit toothed belt guard.
• ‒ Refit crankshaft belt pulley. When doing this note the following:
• ‒ The securing bolt and washer for the pulley and toothed belt sprocket must be renewed.
• ‒ When installing the pulley observe the fixing arrangement to toothed belt sprocket.
• ‒ Tightening procedure for the new oiled bolt: 90 Nm + 1/4 turn (90°) further.

Tightening torques

Note:

The assembly mounting securing bolts are stretch bolts and must be replaced.

→ Engine mounting

A = 40 Nm + 1/4 turn (90°) further
B = 50 Nm
C = 20 Nm + 1/8 turn (45°) further

• ‒ Install ribbed belt again.

Note:

When installing the ribbed belt ensure that it sits correctly in the pulleys.

• ‒ Fit console on cylinder head.
• ‒ Install engine mounting.
• ‒ Install air inlet to air cleaner.
• ‒ Install power assisted steering reservoir.
• ‒ Install noise insulation tray.