Volkswagen Workshop Service and Repair Manuals

Checking semi-automatic toothed belt tensioning roller

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Counterhold tool -3415-

t	Pins -3415/1-

t	Torque wrench (5...50 Nm) -V.A.G 1331-

t	Torque wrench (40...200 Nm) -V.A.G 1332-

Checking main drive tensioning roller Test procedure –  Remove air cleaner housing → Chapter. –  Remove upper toothed belt guard. –  Unbolt coolant reservoir and place to side. –  Remove engine splash guard. –  Remove front right wheel housing liner → General body repairs, exterior; Rep. Gr.66 –  Mark the direction of rotation of the poly V-belt and remove belt → Chapter. The engine must be lowered slightly as follows to enable the crankshaft pulley to be removed:

–  Fit support bracket 10-222A with frame -10 - 222 A /1- as shown. –  Remove upper securing bolt from lower toothed belt guard under engine mounting.

–  Take up weight of engine and remove securing bolts -A-.

–  Remove securing bolts -B- and remove assembly mounting. –  Remove engine bracket on cylinder head. –  Lower engine until the belt pulley securing bolt is accessible.

–  Remove pulley securing bolt and toothed belt pulley. Hold belt pulley with counterhold -3415- and pin 3415/1. –  Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt pulley. –  Remove poly V-belt tensioning element on vehicles with an air conditioning system. –  Remove lower toothed belt guard. –  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. Checking coupling drive tensioning roller: Test procedure

–  Note position of tensioning roller indicator -1-. Press toothed belt forcefully with thumb -arrow-. 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. If both tensioning rollers are OK –  Refit lower toothed belt guard. –  Refit crankshaft pulley. When doing this, note the following t  The belt pulley securing bolt and the toothed belt pulley must be renewed. t  When installing pulley, observe fixing arrangement to toothed belt pulley. t  Tightening procedure for the new oiled bolt: 90 Nm + 1/4 turn (90°) further. –  Fit engine bracket to cylinder head. Torque setting: 50 Nm. –  Install poly V-belt tensioning element again on vehicles with an air conditioning system. –  Install engine mounting. Prescribed torque → Chapter. –  Install top toothed belt guard. –  Installing poly V-belt → Chapter.   Note When installing poly V-belt, ensure that belt seats correctly in pulley. –  Install front right wheel housing liner → General body repairs, exterior; Rep. Gr.66 –  Install engine splash guard. –  Bolt on coolant expansion tank. –  Install air cleaner housing → Chapter.