Contents: Tension ↓ Replacement ↓
Please note: Vehicles manufactured from 8/93 onwards, as well as models with a 1.9L turbodiesel engine and with G60 and VR6 engines, are equipped with a poly V-belt instead of a V-belt. The poly V-belt drives the alternator, coolant pump and, depending on the engine and vehicle version, the fan, power steering pump and air conditioning compressor. On models with a 4-cylinder engine, the power steering pump is driven by an additional conventional V-belt, see chapter "Steering".
As part of maintenance, the poly V-belt should be checked for excessive wear (fringing of the side surfaces, transverse cracks), and traces of oil. If necessary, the poly V-belt should be replaced.
Tension
Note: On all models there is no need to tighten the poly V-belt, as the spring-loaded tension roller maintains the belt tension constant. For the position of the tension roller, see the section "Replacement".
Loosen generator mounting bolts "1" and "2" by at least 1 turn.
Using tension lever 3297 or a crowbar, press the generator down until it stops, so that it can move well. There is a spring on the bottom of the generator that presses it up.
With the generator still released, start the engine and let it idle for about 10 seconds. The belt tension is adjusted automatically. Stop the engine.
Tighten bolt "2" first, then bolt "1" to a torque of 25 Nm.
Attention: Do not lean on the generator or touch the belt.
Replacement
Caution: When applying the poly V-belt, ensure that it is positioned exactly in the middle of all rollers and belt pulleys.
4-cylinder engine (except for the G60 engine)
Remove the V-belt from the power steering pump drive, see chapter "Steering".
Models without tension roller: release the generator and press it down, see section "Tension". Remove the poly V-belt.
Models with tension roller: move the tension roller with the help of lever 3299 and remove the poly V-belt from the alternator belt pulley. If there is no special tool, with some skill you can make a suitable lever yourself. Remove the poly V-belt.
Put on a new belt.
Use a special tool to loosen and remove.
Start the engine and check the operation of the belt.
G60 Engine
Remove the power steering pump drive V-belt, see chapter "Steering".
Using a special tool (VW 3191), compress the spring and release the tensioner.
Remove the poly V-belt and install a new one.
Use a special tool to loosen and remove.
Start the engine and check the operation of the belt.
VR6 Engine
Remove the air filter housing.
Screw bolt MB into threaded hole "A" of the tension roller until the poly V-belt loosens.
Remove the poly V-belt and install a new one.
Remove the M8 bolt from the tension roller.
Start the engine and check the operation of the belt.
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