Replacing Drive Belt

WARNING: This page is about a different variant/trim than selected.

Tool overview for drive belt

Fig 1: Drive Belt Routing

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Tool overview for drive belt

1	> 9952 - Ring wrench
2	> 9866/1 - Spreader
3	> 9953 - Socket-wrench insert
not shown	> V.A.G 1331A - Torque wrench, 6-50 Nm/4.5-37 ftlb.

Drive belt routing (view with deflection roller instead of PDCC pump):

Fig 2: Drive Belt Routing Diagram (Engine Removed Without Heat Shield)

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Drive belt routing (engine removed without heat shield)

1	Drive belt
2	Generator pulley
3	PDCC pump deflection roller or pulley
4	Air-conditioning compressor pulley
5	Crankshaft vibration damper
6	Coolant pump pulley
7	Tensioning roller for belt tensioner

Vehicles with PDCC: Loosen screws -2- on the PDCC pump .

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Pulley on pump
Slacken the drive belt -1- .
> 9952 - Ring wrench-3- must be fitted on the hexagon of the tensioner -2- . Then, turn it clockwise as far as it will go and hold it at this position.

Remove drive belt -1- from the pulley on the generator.

Carefully guide the tensioning roller back to its original position.

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Tensioning/slackening drive belt
The drive belt can be cut to facilitate removal.
Vehicles with PDCC: Unscrew screws -2- on the PDCC pump and remove pulley -1- .

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Pulley on pump
Vehicles without PDCC: Remove deflection roller.
> 137719 REMOVING AND INSTALLING DEFLECTION ROLLER
Remove screw (M10 x 115) -3- using > V.A.G 1331A - Torque wrench, 6-50 Nm/4.5-37 ftlb.-1- and > 9953 - socket-wrench insert-3- .
Unscrew screw fully and put it into the bore in the body.

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Screw for engine carrier and spacer sleeve

Remove spacer sleeve.

> 9866/1 - Spreader-1- must now be fitted between the engine carrier and coolant guide (unit carrier) -Arrows- . Then push the engine carrier back by 2 mm by turning the spreader clockwise at the hexagon.

Hold the spreader securely with your hand when screwing it!

Remove spacer sleeve.

Loosen the spreader by turning it anti-clockwise at the hexagon.

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Using special tool Spreader

1	Special tool Spreader
dimension X	Max. 2.5 mm

Information

Check for foreign objects in the grooves of the pulley.

Check pulleys for damage.
Guide new drive belt -1- using a plastic wedge -2- past the vibration damper -3- and heat shield -4- .

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Drive belt with plastic wedge
Position drive belt on the running track on the vibration damper.

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Drive belt on vibration damper
Position the drive belt -1- on the coolant pump pulley.

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Drive belt on coolant pump
Vehicles with PDCC: Fit PDCC pump pulley -1- and fit screws -2- .

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Pulley on pump
Vehicles without PDCC: Install deflection roller.
> Tightening torque 45 Nm (33 ftlb.)

> 137719 REMOVING AND INSTALLING DEFLECTION ROLLER

Fit the drive belt on the pulleys for the air-conditioning compressor -4- , PDCC pump or deflection roller -3- and generator -2- .

Then, pre-position it on the tensioning roller -7- .

Drive belt routing (view with deflection roller instead of PDCC pump):

Fig 3: Drive Belt Routing Diagram (Engine Removed Without Heat Shield)

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Drive belt routing (engine removed without heat shield)

1	Drive belt
2	Generator pulley
3	PDCC pump/deflection roller pulley
4	Air-conditioning compressor pulley
5	Crankshaft vibration damper
6	Coolant pump pulley
7	Tensioning roller for belt tensioner

Tension the drive belt -1- .
> 9952 - Ring wrench-3- must be fitted on the hexagon of the tensioner -2- . Then, turn it clockwise as far as it will go and hold it at this position.

Fit drive belt -1- .

Carefully guide the tensioning roller back to its original position.

Check that the drive belt is fitted correctly.

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Tensioning/slackening drive belt

Install spacer sleeve.

Hold the spreader securely with your hand when screwing it!

Fit spacer sleeve.

Loosen the spreader by turning it anti-clockwise at the hexagon and remove it.

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Using special tool Spreader

1	Special tool Spreader
dimension X	Max. 2.5 mm

Fit screw (M10 x 115) -3- and tighten using > V.A.G 1331A - Torque wrench, 6-50 Nm/4.5-37 ftlb.-1- and > 9953 - socket-wrench insert-3- .
Observe different tightening torque for using the special tool!

> Tightening torque 53 Nm (39.1 ftlb.)

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Screw for engine carrier and spacer sleeve
Vehicles with PDCC: Tighten screws -2- .
> Tightening torque 23 Nm (17 ftlb.)

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Pulley on pump