Retrofitting auxiliary drive (genuine parts set) — VW

Retrofitting auxiliary drive (genuine parts set)
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Caution
When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
To avoid damage to lines, ensure sufficient clearance from all moving or hot components.
Note
If an auxiliary drive is retrofitted to a vehicle, noise insulation should also be fitted
Electronic Parts Catalogue
.
Procedure
For the following work measures, the engine needs to be locked. Engage a gear to do so.
Cut out cowling in marked area
1
.
Deburr sharp edges if there are any.
Remove poly V-belt for viscous fan
Chapter
.
Remove poly V-belt
Chapter
.
Remove vibration damper
Chapter
.
Align position of hub relative to vibration damper
arrows
, and make a corresponding mark on vibration damper.
Install hub
1
with vibration damper
2
.
Tighten bolts to specified torque.
Note
The hub fits in one position only. If positioned incorrectly, the bolt holes are offset.
Installation is possible in one position only, i.e. when the hole in the vibration damper is located over the projection on the toothed belt pulley
Chapter
.
Install poly V-belt
Chapter
.
Install poly V-belt for viscous fan
Chapter
.
Install auxiliary drive pulley
1
.
Tighten bolts to specified torque.
Note
Pay attention to the marks indicating the position of the pulley relative to the hub and that of the vibration damper.
The auxiliary drive belt pulley fits in one position only. If incorrectly positioned, the bolt holes are offset.
Clip plug
arrow
into place.
Mount
bracket
5
on cylinder crankshaft, observing following procedure:
On vehicles with single turbo, thrust pad
arrow
must also be used.
Manually locate all bolts for securing bracket and spacer plate.
Tighten bolts
1 ... 3
to specified torque.
After having installed air conditioner compressor, tighten bolt
4
to specified torque.
Install air conditioner compressor or alternator.
Tighten bolt
4
to specified torque.
Fit tensioning element
2
to bracket
1
.
Tighten bolts
arrows
.
Install poly V-belt for auxiliary drive
Chapter
.
Always check belt running after completing work.
Specified torque
Chapter
“
Assembly overview - auxiliary drive, 2nd air conditioner compressor (genuine parts set)
”
Chapter
“
Assembly overview - auxiliary drive, 2nd alternator (genuine parts set)
”