Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ Before removing the ribbed belt mark direction of rotation and observe when installing. Installing opposite to the direction of rotation leads to belt damage!
• ◆ If damage is established, to prevent failure or functional faults the ribbed belt must be replaced immediately!

Belt drive without tensioning roller

Belt drive with tensioning roller

Removing ribbed belt

Special tools, testers and auxiliary items

• ◆ 3297 Lever

• ‒ → Loosen alternator securing bolts -1- and -2- at least one turn.
• ‒ Lower alternator with lever 3297 and remove ribbed belt from generator pulley.
• ‒ Removing P.A.S. vane pump ribbed belt:

=> Running gear; Repair group 48; assembly overview: vane pump, reservoir, hydraulic pipes, removing and installing V-belt.

• ‒ Remove ribbed belt.

Installing ribbed belt

• ‒ Install alternator with bolts -1- and -2-.

The tensioning spring guide cap must locate in the mounting on the alternator!

• ‒ Screw bolt -1- in until the threaded bush contacts the bracket. The alternator must still move freely.
  
• ‒ Place ribbed belt on crankshaft pulley, vibration damper and coolant pump pulley.

Note:

• ◆ When installing used ribbed belts observe the direction of rotation marked on removal!
• ◆ When fitting the belt ensure the ribbed belt locates correctly in the pulleys!

• ‒ Installing P.A.S. vane pump V-belt:

=> Running gear; Repair group 48; assembly overview: vane pump, reservoir, hydraulic pipes, removing and installing V-belt.

• ‒ Lower alternator 3297 and fit ribbed belt to alternator pulley.

Note:

If the engine is out of the vehicle, do not proceed further until engine has been refitted.

• ‒ → Push alternator down at least 3 times onto stop with tensioning lever 3297 to ensure the alternator moves freely.
• ‒ With the alternator still loose run engine for at least 10 secs. at idling speed.

• ‒ Switch off engine and tighten alternator securing bolts:

→ 1.Securing bolt -2- , 25 Nm

2.Securing bolt -1- , 25 Nm

Note:

When tightening keep to the sequence given, do not use the alternator for support and do not touch ribbed belt.

Belt drive with tensioning roller

Removing ribbed belt

Special tools, testers and auxiliary items

• ◆ 3299 Lever

• ‒ → Lift tensioner with lever 3299 and remove ribbed belt from the alternator pulley.
• ‒ Removing P.A.S. vane pump V-belt:

=> Running gear; Repair group 48; assembly overview: vane pump, reservoir, hydraulic pipes, removing and installing V-belt.

• ‒ Remove ribbed belt

Installing ribbed belt

• ‒ Fit ribbed belt to crankshaft pulley/vibration damper and coolant pump pulley.

Note:

• ◆ When fitting used ribbed belts observe the direction of rotation marked on removal!
• ◆ When fitting the belt ensure the ribbed belt locates correctly in the pulleys!

• ‒ Install P.A.S. vane pump V-belt:

=> Running gear; Repair group 48; assembly overview: vane pump, reservoir, hydraulic pipes, removing and installing V-belt.

→ Belt drive without A/C compressor

• ‒ Lift tensioning roller with 3299 and fit ribbed belt to generator pulley

Note:

When fitting ribbed belt ensure it locates correctly in the pulleys!

• ‒ Lower tensioning roller onto ribbed belt with 3299

→ Belt drive with A/C compressor