Removing and installing ribbed belt (poly V-belt) — VW

Notes:

If a used belt is to be reused, mark direction of rotation before removing. When installing used ribbed belts (poly V-belts) observe direction of rotation marked on removal. Installing opposite to the direction of rotation leads to belt damage!

There is no requirement to adjust the ribbed belt (poly V-belt) tension, as a spring loaded tensioner guarantees the best possible belt tension.

Work sequences:

Petrol engines · =>from page . 27-67

Diesel engine · =>from page . 27-71

Special tools, testers, measuring instruments and auxiliary items required

3090 Conrod support

4Cylinder 1.6 l, 1.8 l and 2.0 l injection engines with power steering vane pump and air conditioner compressor

Remove the 2 screws along each side.
Take engine cover off downwards.

Removing engine compartment cover, engine side
Remove bolt/screw -1-.
Release clips -2-.
Take cover out of retainers -3-.

Note:

Do not reuse the clips, renew clips each time cover is removed.

Removing ribbed belt (poly V-belt)

Models with a 4 cylinder, 1.6 l injection engine:

Remove engine cover:

=> Workshop Manual of appropriate injection system

Models with a 4 cylinder, 2.0 l injection engine:

Lever cover caps out -arrows- and remove nuts found underneath.
Remove nut -1-.
Pull oil dipstick out.
Take engine cover off upwards.

Models with a 4 cylinder, 1.8 l injection engine:

Lever cover cap out -1- for engine cover securing nuts and remove combi-nut found underneath -2-.
Pull engine cover out of retainers and take cover out upwards.

When installing tighten combi-nut to 7 Nm.

Continuation for all models:

Mark direction of rotation of ribbed belt (poly V-belt) if the belt is to be reused.
Turn tensioning device in direction of arrow to relieve tension on ribbed belt.

Note:

The tensioner can be locked with a 4.5 mm ø and approx. 55 mm long drift. Conrod support 3090 can be used on models which do not have a headlight washer system.

Remove ribbed belt (poly V-belt).

Installing ribbed belt (poly V-belt)

Continuation for all models:

Notes:

When reinstalling used ribbed belts (poly V-belts) observe the direction of rotation marked on removal!
Ensure, before installing ribbed belt, that all ancillaries (alternator, air conditioner compressor, power assisted steering vane pump) are secured tightly.
Ensure ribbed belt (poly V-belt) is seated correctly in belt pulley when installing.

Fit ribbed belt (poly V-belt).
Remove 4.5 mm ø drift or conrod support 3090.
Start engine and check belt running.
Install engine cover.
Install centre and right-hand noise insulation engine compartment covers.

4Cylinder diesel engine with power assisted steering vane pump and air conditioner compressor

First remove the 4 screws along each side, then remove the 2 rear screws.
Take engine cover off downwards.

Removing engine compartment cover, engine side
Remove bolt/screw -1-.
Release clips -2-.
Take cover out of retainers -3-.

Note:

Do not reuse the clips, renew clips each time cover is removed.

Lever cover caps out -arrows- and remove nuts found underneath.
Remove nut -1-.
Pull oil dipstick out.
Remove engine cover.
Remove charge air pipe between charge air cooler and exhaust turbocharger.

=> 4Cylinder Diesel engine, mechanics; Repair group 21; Charge air system with turbocharger; Removing and installing parts of the charge air cooling system.
4Cylinder Diesel engine, mechanics
Charge air system with turbocharger
Removing and installing parts of the charge air cooling system.

Mark direction of rotation of ribbed belt (poly V-belt) if the belt is to be reused.

Removing ribbed belt (poly V-belt)

Swing tensioning roller in direction of arrow using a flat 16 mm ring spanner on tensioning lever.
Remove ribbed belt (poly V-belt).

Note:

Take ribbed belt (poly V-belt) off idler roller first.

Installing ribbed belt (poly V-belt)

Notes:

When reinstalling used ribbed belts (poly V-belts) observe the direction of rotation marked on removal!
Ensure, before installing ribbed belt, that all ancillaries (alternator, air conditioner compressor, power assisted steering vane pump) are secured tightly.
On vehicles with air conditioner remove ribbed belt from idler roller first and fit on idler roller last when installing.

Ensure ribbed belt (poly V-belt) is seated correctly in belt pulley when installing.

Swing tensioning roller in direction of arrow using a flat 16 mm ring spanner on tensioning lever.
Fit ribbed belt (poly V-belt).
Install charge air pipe
Start engine and check belt running.
Install engine cover.
Install centre and right-hand noise insulation engine compartment covers.