Volkswagen Cars 2000-05

Accessory Drive Belts 4

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Removal & Installation





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Fig. When removing ribbed belts, it's a good idea to mark the direction of the belt if it is to be reused



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Fig. Ribbed style serpentine belt

If a belt must be replaced, the driven component must be loosened and moved to its extreme loosest position (usually by moving it toward the center of the motor). On models with automatic belt adjusters, refer to the illustrations for information on relieving belt tension. After removing the old belt, check the pulleys for dirt or built-up material which could affect belt contact. Carefully install the new belt, it may appear to be just a little too small to fit over the pulley flanges. Fit the belt over the largest pulley (usually the crankshaft pulley at the bottom center of the motor) first, then work on the smaller one(s). Gentle pressure in the direction of rotation is helpful. Some belts run around a third or idler pulley, which acts as an additional pivot in the belt's path. It may be possible to loosen the idler pulley as well as the main component, making your job much easier. Depending on which belt(s) you are changing, it may be necessary to loosen or remove other interfering belts to get at the one(s) you want.

When buying replacement belts, remember that the fit is critical according to the length of the belt, the width of the belt, the depth of the belt and the angle or profile of the V shape (always match up old belt with new belt if possible). The belt shape should exactly match the shape of the pulley; belts that are not an exact match can cause noise, slippage and premature failure.

After the new belt is installed, adjust it for proper tension. This is sometimes a three or four-handed job; you may find an assistant helpful. Make sure that all the bolts you loosened are retightened and that any other loosened belts have the correct tension. A new belt can be expected to stretch a bit after installation so be prepared to re-adjust your new belt.


NOTE
After installing a new belt, run the engine for about 5 minutes and then recheck the belt tension.

  1. On diesel engines, remove the upper charge air pipe (1) with connecting hose (2), but unfastening the bolt/screw (3) and releasing the connector (arrow). Carefully cover or cap any open ends.

    Click image to see an enlarged view

    Fig. On diesel engines, remove the upper charge air pipe (1) with connecting hose (2), but unfastening the bolt/screw (3) and releasing the connector (arrow).

  2.  
  3. Remove any components necessary to access the drive belt.
  4.  
  5. Mark the direction of rotation of drive belt.
  6.  
  7. Use a wrench to turn the tensioner in the direction shown to relieve the belt tension.

    Click image to see an enlarged view

    Fig. Use a wrench to turn the tensioner in the direction of the arrow to relieve the belt tension

  8.  
  9. Lock tensioner in place with locking pin T10060 A, or equivalent.

    Click image to see an enlarged view

    Fig. Use a locking pin to lock the tensioner in place

  10.  
  11. Remove the right sound insulator.
  12.  
  13. Remove drive belt.
  14.  
  15. Inspect the condition of the belt, as outlined in this section and replace if necessary.
  16.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Make sure that all accessories (alternator, air conditioning compressor, power steering pump) are secured tightly before installing the belt.
    2.  
    3. When installing the belt, check the direction of belt rotation and proper seating of belt in belt pulleys.
    4.  
    5. On vehicles without A/C, place the belt over the alternator pulley last.
    6.  
    7. On vehicles with A/C, place the drive belt over air conditioning compressor last.
    8.  
    9. Once the belt installation is complete, start engine and make sure the belt is functioning properly Belt drive with air conditioning compressor
      NOTE
      Engines with an air conditioning compressor are equipped with a double drive belt.



      Click image to see an enlarged view

      Fig. Belt routing-without A/C



      Click image to see an enlarged view

      Fig. Belt routing-with A/C

    10.  

  2.  

1.8L (AWD, Aww And Awp) Engines

NOTE
This procedure requires the use of Locking Pin T10060A, or equivalent tool.


NOTE
Engines with A/C have a double drive belt.

  1. Mark the direction of rotation of the drive belt.
  2.  
  3. Use a wrench to rotate the tensioner in the direction of the arrow until it can be locked.

    Click image to see an enlarged view

    Fig. Use a wrench to rotate the tensioner in the direction of the arrow, as shown, until it can be locked

  4.  
  5. Secure the tensioner using Locking Pin T10060 A, as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Secure the tensioner in place using Locking Pin T10060A

  6.  
  7. Remove sound insulation tray.
  8.  
  9. Remove the ribbed drive belt from the vehicle.
  10.  
  11. Inspect the condition of the belt, as outlined in this section and replace if necessary.
  12.  

To install:

  1. Installation is in reverse order of removal, noting the following.
    1. Ensure, before installing the drive belt, that all accessories (generator, air conditioner compressor, power steering pump) are secured tightly.
    2.  
    3. Note previously marked direction of belt rotation and be sure that it is seated correctly on pulley.
    4.  
    5. In vehicles without A/C system, lay drive belt last on the generator.
    6.  
    7. In vehicles with A/C system, lay drive belt last on the A/C compressor.
    8.  

  2.  
  3. After completing the belt installation, repairs always start the engine and make sure the belt is properly installed.

    Click image to see an enlarged view

    Fig. Drive belt routing-1.8L (AWD, AWW, AWP) engines without A/C



    Click image to see an enlarged view

    Fig. Drive belt routing-1.8L (AWD, AWW, AWP) engines with A/C

  4.  

1.9L (Alh) Diesel Engine
  1. Remove the right sound damper cover.
  2.  
  3. Remove the charge air tube between charge air cooler and turbocharger
  4.  
  5. Mark the direction of rotation of drive belt.
  6.  
  7. Use a 16mm flat box-end wrench at the tensioning lever to pivot idler roller in direction of arrow, as shown in the illustration.

    Click image to see an enlarged view

    Fig. Use a 16mm flat box-end wrench at the tensioning lever to pivot idler roller in direction of arrow, as shown in the illustration-1.9L (ALH) diesel engine

  8.  
  9. Remove the belt.
    NOTE
    On vehicles without A/C system, first remove drive belt from generator and install drive belt to generator last. On vehicles with A/C system, first remove drive belt from idler roller and install drive belt to idler roller last.

  10.  
  11. Inspect the condition of the belt, as outlined in this section and replace if necessary.
  12.  

To install:

  1. Installation is the reverse of the removal procedure. When installing the drive belt ensure that the belt is seated correctly in the belt pulleys.
  2.  
  3. After completing the belt installation, repairs always start the engine and make sure the belt is properly installed.

    Click image to see an enlarged view

    Fig. Drive belt routing-1.9L ALH Engine without A/C



    Click image to see an enlarged view

    Fig. Drive belt routing-1.9L ALH Engine without A/C

  4.  

1.9L (Bew) Diesel Engine

NOTE
This procedure requires the use of Locking Pin T10060, or equivalent tool.

  1. Remove the right side sound insulation tray.
  2.  
  3. Mark the direction of rotation of poly V-belt.
  4.  
  5. Use a wrench to turn the tensioner in the direction of the arrow to relieve belt tension.

    Click image to see an enlarged view

    Fig. Use a wrench to turn the tensioner in the direction of the arrow to relieve belt tension

  6.  
  7. Lock the tensioner with retaining pin T10060, or equivalent.

    Click image to see an enlarged view

    Fig. Lock the tensioner with retaining pin T10060, or equivalent

  8.  
  9. Remove the V-belt.
  10.  
  11. Inspect the condition of the belt, as outlined in this section and replace if necessary.
  12.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Before installing the poly V-belt, ensure that all ancillaries (Generator, air conditioning compressor, power steering pump) are secured tightly.
    2.  
    3. When installing the poly V-belt, check the direction of belt rotation and for proper seating of the belt in the pulleys.
    4.  
    5. For vehicles without air conditioning, put the poly V-belt over the Generator pulley last.
    6.  
    7. For vehicles with air conditioning, put the poly V-belt over the air conditioning compressor pulley last.
    8.  

  2.  
  3. After completing the belt installation, repairs always start the engine and make sure the belt is properly installed.

    Click image to see an enlarged view

    Fig. Belt routing-1.9L (BEW) diesel engines without A/C



    Click image to see an enlarged view

    Fig. Belt routing-1.9L (BEW) diesel engines with A/C

  4.  

2.0L (Aeg, Avh, Azg, Bbw, Bev) Engines

NOTE
This procedure requires the use of Locking Pin T20167, or equivalent tool.

  1. Remove the right side sound insulation.
  2.  
  3. Remove the engine cover.
  4.  
  5. Mark direction of rotation of poly V-belt.
  6.  
  7. Use a wrench to rotate the tensioner in direction of the arrow to relieve tension from the V-belt.

    Click image to see an enlarged view

    Fig. Use a wrench to rotate the tensioner in direction of the arrow to relieve tension from the V-belt

  8.  
  9. Lock the tensioner in place using locking pin T20167.
  10.  
  11. Remove the V-belt.
  12.  
  13. Inspect the condition of the belt, as outlined in this section and replace if necessary.
  14.  

To install:

  1. Installation is the reverse of the removal procedure. Note the following:
    1. Ensure, before installing poly V-belt, that all ancillaries (Generator, air conditioning compressor, power steering pump) are secured tightly.
    2.  
    3. When installing the poly V-belt observe belt direction of rotation and ensure that the belt is seated correctly in the belt pulleys.
    4.  
    5. On vehicles which do not have an air conditioning system, place the drive belt over the Generator pulley last.
    6.  
    7. For models with an air conditioning, place the poly V-belt over the air conditioning compressor last.
    8.  
    9. After completing the procedure, start the engine and make sure the belt is operating properly.

      Click image to see an enlarged view

      Fig. Drive belt routing-2.0L engines without A/C



      Click image to see an enlarged view

      Fig. Drive belt routing-2.0L engines with A/C

    10.  

  2.  

2.8L (Afp) Engine

NOTE
This procedure requires the use of a M8x80 hex head bolt.

  1. Remove right sound damping tray:
  2.  
  3. Mark direction of travel of the "V" ribbed drive belt.
  4.  
  5. Screw an 8 mm x 80 bolt into the tapped hole (A) of belt tensioner until the pressure is released from the drive belt.
    WARNING
    Screw the bolt in only far enough to make it possible to remove the drive belt. Otherwise, the belt tensioner housing can be damaged.



    Click image to see an enlarged view

    Fig. Screw an 8 mm x 80 bolt into the tapped hole (A) of belt tensioner until the pressure is released from the drive belt

  6.  
  7. Remove the drive belt.
  8.  

To install:


NOTE
Before installing the "V" drive belt, make sure that all the assemblies (Generator, air conditioning compressor, power steering pump) are tightly mounted.

  1. When installing the drive belt , note the direction of travel and make sure the belt is correctly seated in the belt pulleys.

    Click image to see an enlarged view

    Fig. When installing the drive belt , note the direction of travel and make sure the belt is correctly seated in the belt pulleys-2.8L (AFP) engine

  2.  
  3. Route the belt correctly on the pulleys.
  4.  
  5. Remove 8 mm bolt from tensioner.
  6.  
  7. The remainder of installation is the reverse of the removal procedure.
  8.  
  9. Start engine and check to make sure the belt is operating properly.
  10.  

2.8L (Bdf) Engine

NOTE
This procedure requires the following special tools and equipment, or their equivalents:



VAS 5024 Assembly tool for spring-type clips
 
Hex bolt M8x45
 


NOTE
Mark drive belt direction of rotation before removing. Make sure drive belt is seated correctly in pelt pulley when installing.

  1. Remove engine cover.
  2.  
  3. Place a rag under the return hose (blue marking) to catch any leakage, then disconnect the return hose.

    Click image to see an enlarged view

    Fig. Place a rag under the return hose to catch any leakage, then disconnect the return hose (1). The return hose has a blue marking

  4.  
  5. Plug the lines to avoid contamination of fuel system.
  6.  
  7. Removing right hand insulation tray:
  8.  
  9. Mark direction of rotation of drive belt.
  10.  
  11. Screw an M8x45 bolt into threaded hole (A) of tensioning element until drive belt is no longer under tension.
    WARNING
    Screw the bolt in enough so that the drive belt can be removed and no further, or the tensioner element housing may be damaged.



    Click image to see an enlarged view

    Fig. Screw an M8x45 bolt into threaded hole (A) of tensioning element until drive belt is no longer under tension

  12.  
  13. Remove drive belt.
  14.  
  15. Inspect the condition of the belt, as outlined in this section and replace if necessary.
  16.  

To install:


NOTE
Make sure, before installing the drive belt, that all accessories (alternator, air conditioning compressor, power steering pump) are secured tightly.

  1. Installation is the reverse of the removal procedure, noting the following:
    1. When installing the drive belt observe belt direction of rotation and that the belt is seated correctly in the belt pulleys.

      Click image to see an enlarged view

      Fig. Make sure the belt is properly routed during installation-2.8L (BDF) engine

    2.  
    3. Install drive belt.
    4.  
    5. Remove M8 bolt from tensioner.
    6.  
    7. After finishing the procedure, start engine and check to be sure the belt is operating properly.
    8.  
    9. Install right-hand insulation tray:
    10.  
    11. Install engine cover.
    12.  

  2.  

4-Cylinder Gasoline Engines
  1. Set the lock carrier to service position, as outlined in the Engine Mechanical Section.
  2.  
  3. Mark rotational direction of drive belt if to be reused.
    WARNING
    Make sure to note or mark the proper rotational direction of the belt before removing it. If the belt is installed in the wrong direction, the belt will be damaged.

  4.  
  5. Rotate the tensioner in the direction of the arrow shown in the illustration to relieve the belt tension.
  6.  
  7. Lock the tensioner using drift 3204, or equivalent drift..

    Click image to see an enlarged view

    Fig. Rotate the tensioner in the direction of the arrow to relieve the belt tension, then lock the tensioner using a suitable drift

  8.  
  9. Remove the drive belt.
  10.  
  11. Remove the fan from viscous fan pulley.
  12.  
  13. Secure the belt pulley to the viscous fan pulley using a 5mm drift.
  14.  
  15. Unfasten the bolt from the viscous fan pulley, using an 8mm socket-head wrench, then remove the viscous fan pulley together with belt pulley.

    Click image to see an enlarged view

    Fig. Secure the belt pulley to the viscous fan pulley using a 5mm drift (1). Unfasten the bolt from the viscous fan pulley, using an 8mm socket-head wrench (2), then remove the viscous fan pulley together with belt pulley

  16.  
  17. Matchmark the installed position of the 2-part belt pulley for the water pump.
  18.  
  19. Lock or secure the belt pulley of the power steering pump with a drift.
  20.  
  21. Unbolt the 2-part belt pulley for the water pump, then remove the drive belt.

    Click image to see an enlarged view

    Fig. Secure the power steering pump pulley with a drift, then unbolt the 2-part water pump pulley and remove the belt

  22.  

To install:

  1. Attach the 2-part belt pulley to coolant pump and install new a belt between the water pump and power steering pump.
  2.  
  3. Tighten the belt pulley evenly until the belt has moved to outside of its running surface. If necessary, turn the power steering pulley or water pump pulley.
  4.  
  5. Secure the power steering pump in place with drift, then tighten the pulley-to-water pump bolts to 18 ft. lbs. (25 Nm).
    NOTE
    It is not necessary to adjust the drive belt tension with shims.

  6.  
  7. Slide the viscous fan in, then install the drive belt at the viscous fan.
  8.  
  9. Tighten the belt pulley to viscous fan pulley bolts to 22 ft. lbs. (30 Nm).
  10.  
  11. Tighten the viscous fan pulley to 33 ft. lbs. (45 Nm).
  12.  
  13. Install the drive belt.
  14.  
  15. Tension the drive belt. You must remove the drift to perform this.
    NOTE
    When installing the belt, make sure it is properly routed in the pulleys.

  16.  
  17. Start engine and make sure the belt is operating properly.
  18.  

 
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