Thermo Tension Roller - Installing
Group: 13Number: 97-03
Date: Feb. 21, 1997
Subject:
Thermo Tension Roller, Installing
Model(s):
Golf/GTI/Jetta/Cabrio 2.0L 1997 -->
Condition
Toothed drive belt (camshaft drive) noisy.
Service
Use the following procedure and install a thermo tension roller.
Thermo tension roller, Part No. 050 109 479A
CAUTION!
Part Numbers are for reference only.
Always check with your Parts Dept. for the latest information.
Thermo tension roller, installing
(1997-->)
Required tools
^ Ribbed belt installation tool, 3299
^ Two-pin spanner, Hazet 2587, V159 or US4493
Removing ribbed belt and v-belt
- Remove air box w/heat stove pipe and intake boot.
- Release tension on ribbed belt tensioner with VW 3299 and remove ribbed belt at Generator.
- Remove ribbed belt tension roller and upper toothed belt guard
- Remove lower bumper dust cover and accessory drive belt covers.
- Hold hydraulic pump pulley with VAG 1590 or a mandrel and remove fasteners for coolant pump pulley.
- Remove coolant pump pulley and v-belt.
Removing toothed belt
- Remove vibration damper/pulley.
- Turn flywheel (A) or driveplate (B) to align mark (arrow) and place No. 1 cylinder at TDC.
- Remove lower toothed belt guard.
- Remove fastener for toothed belt tension roller and remove toothed belt and roller.
Note:
Mark the running direction on the toothed belt.
- Remove toothed belt tension roller stud.
- Assemble new thermo tension roller and install on engine block.
- Torque collar screw and 6 mm fastening nut.
CAUTION!
DO NOT turn the camshaft while any piston is at TDC position. There is risk of damage to valves and piston crowns.
Installing toothed belt
- Align mark on camshaft drive sprocket with mark on cylinder head cover and/or toothed belt guard.
- Place toothed belt on crankshaft gear (note running direction of belt).
- Turn tension roller to right using two-pin spanner -B-, one pin inserted in hole in roller, one pin in slot at bottom of roller pivot bracket (--> -arrows- in illustration 13-A039) until:
^ piston -1- is driven all the way out
^ piston -2- lifts up approx. 1.0 mm (0.040 in.)
- Tighten mounting bolt -3- by hand
- Rotate engine 2 revolutions in running direction
- Counter-hold thermo tension roller with two-pin spanner and tighten mounting bolt -3- to 25 Nm (18 ft lb.).
- Install lower belt guard.
- Install vibration damper/pulley.
Installing v-belt and ribbed belt
- Install ribbed belt tension roller.
- Adjust tension on ribbed belt tensioner with 3299 and position belt.
- Position v-belt and bolt coolant pump pulley to coolant pump.
- Install upper belt guard.
- Install air box w/heat stove pipe and intake boot.
Tightening torques
Torx bolt, Pt. No. N 903 659 02 25 Nm (18 ft lb..)
Collar screw, Pt. No. 058 109 281 15 - 20 Nm (11 - 15 ft lb..)
Bolt/washer asm (2), Pt. No. N 902 809 01
7 - 11 Nm (62 - 97 in. lb.)
Nut, Pt. No. N 011 006 27 7 - 11 Nm (62 - 97 in. lb..)
CAUTION!
Part Numbers are for reference only. Always check with your Parts Dept. for the latest information.