Volkswagen Workshop Service and Repair Manuals

Checking main drive tensioning roller

–  Remove cover above camshaft housing -arrows-. –  Remove air filter → Fig.. –  Remove upper toothed belt guard. The engine must be lowered slightly as follows to enable the crankshaft pulley to be removed:

–  Fit support bracket -10 - 222 A- with frame -10 - 222 A /1- as shown. –  Remove power-assisted steering reservoir and lay to side. –  Remove upper securing bolt from lower toothed belt guard beneath engine bracket. –  Take up weight of engine and remove right engine bracket as shown.

–  Unscrew securing bolts -B- and completely remove assembly mounting. –  Remove engine bracket on cylinder head. –  Remove right noise insulation. –  Lower engine until the pulley securing bolt is accessible. –  Mark direction of rotation of poly V-belt.

–  Pivot tensioning roller in direction of arrow by turning securing bolt with straight ring spanner. –  Remove poly V-belt.

–  Remove pulley securing bolt and toothed belt pulley. Fix belt pulley with counterhold -3415- and pin -3415/1- (on ATN, AUS, AZD, BCB with counterhold -T10028-). –  Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt pulley. –  Now turn crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1 cylinder.

–  Note position of tensioning roller indicator -arrow-. Press toothed belt forcefully with thumb. The indicator must move. –  Release tension on toothed belt. –  Turn crankshaft two turns in engine direction of rotation. –  Then check position of indicator. It must have returned to its original position. If tensioning roller does not return to its initial position –  Replace tensioning roller.