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Home >> Volkswagen >> 2012 >> Beetle (5C1) L4-2.0L Turbo (CBFA) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Drive Belts, Mounts, Brackets and Accessories >> Drive Belt Tensioner >> Service and Repair

Drive Belt Tensioner: Service and Repair






Ribbed Belt Tensioner

Special tools, testers and auxiliary items required

• Mount (T40093/5) from the Engine Support Supplement Set (T40093)

• Moveable Joint (T40093/4) from the Engine Support Supplement Set (T40093) (quantity: 2)

• Rail with Holes (T40091/2) from the Engine Support Basic Set (T40091)

• Square Pipe (T40091/1) from the Engine Support Basic Set (T40091) (quantity: 2)

• Moveable Joint (T40091/3) from the Engine Support Basic Set (T40091) (quantity: 2)

• Engine Support Bridge (10-222 A)

• Adapter (10-222 A/28)

• Adapter (10 - 222 A/28-1) (quantity: 2)

• Shackle (10-222 A/12)

• Bracket with Spindle and Hook (10-222 A/10)

• Spindle (10-222 A/11)

• Support Bracket (10-222 A/31)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

Procedure

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Danger of causing damage to the coupling element:

• Do not bend the coupling element more than 10°.

• Do not stretch the coupling element.

• Do not damage the wire mesh on the coupling element.

- Remove the noise insulation..

- Remove the exhaust system suspended mount bolts - arrows - from the subframe.






- Remove the pendulum support bolt - 1 -.






- Then, remove the pendulum supports bolts - 2 and 3 - and remove the pendulum support.

- Remove the after run coolant pump bracket bolt - 2 -.






• The after run coolant pump stays in the installed position.

- Remove the lock carrier trim.

- Remove the right front wheel.

- Remove the right wheel housing liner..

- Remove the engine cover. Refer to => [ Engine Cover ] Service and Repair.

- Remove the plenum chamber cover.

- Remove the left and right side lock carrier bracket bolts - arrows -.






- Remove the lower mount from the adapter (10-222 A/28) and replace it with adapter (10-222 A/28-1).






- Remove the bolts - arrows - from the adapter (10-222 A/28-1).

- Use the bolts from the adapter (10-222 A/28-1) to secure the adapter (10-222 A/28) and the adapter (10-222 A/28-1). Do not use the bolts for the lock carrier bracket.






- Bolt - arrows - tightening specification: 8 Nm.

A second technician is needed to install the engine support bridge (10-222 A) to the vehicle in order to prevent the engine support bridge from tipping.

Install the engine support bridge as follows:






1. Adapter (10-222 A/31-2)

2. Moveable joint (T40091/3)

3. Adapter (10-222 A/31-1)

4. Moveable joint (T40093/4)

5. Square pipe (T40091/1)

6. Adapter (10-222 A/28) with adapter (10-222 A/28-1)


- Install the moveable joint (T40091/3) (- 2 -) onto the engine support bridge (10-222 A) square pipe.

• The moveable joint (T40091/3) (- 2 -) bolts, when installed on the engine support bridge (10-222 A) face the direction of travel.

- Install the engine support bridge (10-222 A) to the strut towers and have a second technician hold it to prevent it from falling over.

- Install the square pipes (T40091/1) (- 5 -) on the left and right sides, through the adapters (10-222 A/28) (- 6 -) and install the moveable joints (T40093/4) (- 4 -) onto the square pipes.

- Install the rail with holes (T40091/2) (- 8 -) with the mounts (T40093/5) (- 7 -) into the moveable joint (T40093/4) (- 4 -).






1. Adapter (10-222 A/31-2)

2. Moveable joint (T40091/3)

3. Adapter (10-222 A/31-1)

4. Moveable joint (T40093/4)

5. Square pipe (T40091/1)

6. Adapter (10-222 A/28) with the adapter (10-222 A/28-1)

7. Mount (T40093/5)

8. Rail with holes (T40091/2)

9. Spindle (10-222 A/11)


- Insert the locking pin into the rail with holes (T40091/2) (- 8 -) and secure it with cotter pins.

- Tighten all threaded connections on the engine support bridge (10-222 A) hand tight. Adjust the height of the engine support bridge (10-222 A) parallel over the adapters (10-222 A/28).

- Lightly tension the engine and transmission subassembly by adjusting the spindles (10-222 A/11) (- 9 -).

- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Remove the engine mount to engine mount bracket bolts - arrows -.






- Lower the engine approximately 55 mm.

- Free up the wiring harness - arrow -.






- Remove the bolt - 1 - and remove the ribbed belt tensioner from the accessory bracket.

Installing

Install in the reverse order of removal. Note the following:

• Tightening specifications, refer to => [ Ribbed Belt Drive Overview ] Ribbed Belt Drive Overview.

• For the engine mount tightening specifications, refer to => [ Engine and Transmission Mount Overview ] Engine and Transmission Mount Overview.

- Insert the ribbed belt tensioner - 1 - into the accessory bracket - 3 - and tighten the bolt - 5 -.






• Note the support - 2 - installed location: insert the support tab in the hole in the accessory bracket.

• Note the centering sleeve - 4 -.

- Adjust the engine mount. Refer to => [ Engine and Transmission Mount, Adjusting ] Engine and Transmission Mount, Adjusting.

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