Checking semi-automatic toothed belt tensioner

Special tools and workshop equipment required

• Support - 10 - 222 A-
• Rack - 10 - 222 A /1-
• Counter-hold tool - 3415-
• Pin - 3415/1-
• Torque wrench (5 … 50 Nm) - V.A.G 1331-
• Torque wrench (40… 200 Nm) - V.A.G 1332-

Checking main drive tensioning roller

Test sequence

• Remove upper toothed belt guard.
• Unscrew coolant expansion tank and lay to side.
• Remove engine splash protection.
• Remove front right wheel housing liner: ⇒ General body repairs, exterior; Rep. gr. 66; Removing and installing wheel housing liner.
• Mark the direction of rotation of the poly V-belt and remove belt ⇒ 1.4 Removing and installing poly-V belt.

The engine must be lowered slightly as follows to enable the crankshaft pulley to be removed:

• Fit support bracket - 10 - 222 A- with frame - 10 - 222 A /1- as shown.
• Remove upper securing bolt from lower toothed belt guard beneath engine bracket.

• Take up weight of engine and remove securing bolts -A-.

• Remove securing bolts -B- and remove assembly mounting.
• Remove engine bracket on cylinder head.
• Lower engine until the pulley securing bolt is accessible.

• Remove pulley securing bolt and toothed belt pulley. Hold belt pulley with counterhold - 3415- and pin 3415/1.
• Remove pulley. Refit securing bolt with two washers and tighten to secure toothed belt pulley.
• Remove poly V-belt tensioning element on vehicles with an air conditioning system.
• Remove lower toothed belt guard.
• Turn crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1 cylinder.

• Note position of tensioning roller indicator -arrow-. Press toothed belt forcefully with thumb. The indicator must move.
• Release tension on toothed belt.
• Turn crankshaft two turns in engine direction of rotation.
• Then check position of indicator. It must have returned to its original position.

If tensioning roller does not return to its initial position

• Replace tensioning roller.

Checking coupling drive tensioning roller:

Test sequence

• Note position of tensioning roller indicator -1-. Press toothed belt forcefully with thumb -arrow-. The indicator must move.
• Release tension on toothed belt.
• Turn crankshaft two turns in engine direction of rotation.
• Then check position of indicator. It must have returned to its original position.

If tensioning roller does not return to its initial position

• Replace tensioning roller.

If both tensioning rollers are OK

• Refit lower toothed belt guard.
• Refit crankshaft pulley. Observe the following:

• The belt pulley securing bolt and the toothed belt pulley must be renewed.
• When installing belt pulley, observe fixing arrangement to toothed belt pulley.
• Tightening procedure for the new oiled bolt: ⇒ 2.4 Poly V-belt pulley securing bolt tightening procedure

• Fit engine bracket to cylinder head. Specified torque: 50 Nm
• Install poly V-belt tensioning element again on vehicles with an air conditioning system.
• Install engine assembly mounting. Specified torque ⇒ 1.5 Assembly mountings
• Install lower part of toothed belt guard.
• Install poly V-belt ⇒ 1.4 Removing and installing poly-V belt.

• Install front right wheel housing liner: ⇒ General body repairs, exterior; Rep. gr. 66; Removing and installing wheel housing liner.
• Install engine splash protection.
• Secure coolant expansion tank.