Removing and installing ribbed belt tensioning device — VW

ACV AHY AJA AJT AUF AXG AXL AYC
(Only for vehicles 02.95 ▸ with tensioning roller)

Engine codes AAB, ACV, AJA, AJT, AUF, AXL, AYC

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

3227 Engine stand
V.A.G 1383 A Engine/gearbox jack
V.A.G 1921 Spring-type clip pliers
V.A.G 1331 Torque wrench (5...50 Nm)
V.A.G 1332 Torque wrench (40...200 Nm)
Wooden wedge

Removing

Remove ribbed belt => Page
13-26
.
Removing radiator grille:

=> General body repairs; Repair group 66; Servicing radiator grille
General body repairs
Servicing radiator grille

Engine codes ACV, AUF, AYC

Remove charge air cooler bracket -1-.
Remove charged air cooler with air hoses
=> Page
21-11
, removing and installing parts of charge air cooling.

Continued for all vehicles

Remove left and right-hand securing bolts -2-.
Fold lock carrier and radiator out forwards -arrow-.
Disconnect P.A.S. vane pump hydraulic pipes from engine.

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes
Running gear
Assembly overview: vane pump, reservoir, hydraulic pipes

Unbolt right-hand drive shaft at gearbox:

=> Running gear; Repair group 40; Removing and installing drive shaft
Running gear
Removing and installing drive shaft

Bolt engine stand 3227 onto cylinder block and tighten to approx. 20 Nm.
Lift engine and gearbox lightly with engine/gearbox jack V.A.G 1383 A.
Remove gearbox mountings:

Engine codes AAB, AJA, AJT

=> 5-Speed manual gearbox 02B; Repair group 34; Removing and installing gearbox
5-Speed manual gearbox 02B
Removing and installing gearbox

Engine codes ACV, AUF, AXL, AYC

=> 5-Speed manual gearbox 02G; Repair group 34; Removing and installing gearbox
5-Speed manual gearbox 02G
Removing and installing gearbox

Remove right-hand engine mounting centre bolt(s).

Notes:

When lowering engine ensure that front exhaust pipe does not lie on steering box.
When pushing engine forwards ensure that cables, pipes and hoses are not overstretched.

Lower engine with engine/gearbox jack V.A.G 1383 A as far as possible, push forwards and prevent from swinging back by securing with wooden wedge -arrow-.

Remove ribbed V-belt idler roller -arrow 1-.
Remove ribbed V-belt tensioning roller -arrow 2-.
Remove tensioning device bracket -arrow 3-.
Dismantling and assembling tensioning device => Page
13-3
.

Installing

Install ribbed V-belt tensioning device in reverse sequence.

Tightening torques

Screwed/bolted connection · Tightening torque
Bracket to cylinder block · 70 Nm
Tensioning roller to tensioning lever · 20 Nm
Idler roller to bracket · 20 Nm
Centre engine mounting bolt · M10x60 · 65 Nm