Genuine Volkswagen Cabrio Belt Tensioner

Volkswagen Cabrio Belt Tensioner Parts and Q&A

• Idler Pulley
  026-109-243-L
  Q: How to properly disable the fuel system and replace the Belt Tensioner and Cam Gear on Volkswagen Cabrio?

  A:

  The fuel system should be disabled by removing the wiring connection to the fuel cut-off solenoid before starting work. Avoid any movement of the vehicle using the parking brake and with blockage of the rear wheels. To access the components, take out the auxiliary drivebelt(s) of components. Adjust the engine to TDC on the 1st cylinder, and then take off the upper and bottom part of the outer cover of the Timing Belt. Unscrew the retaining nut at the hub of the tensioner pulley and allow the assembly to swing counterclockwise, which releases the tension of the timing belt. Take out the nut and retrieve the washer and then move the tensioner off of its mounting stud. Clean the tensioner with no solvents that can pollute the bearings. Turn the tensioner pulley manually; hard movement or high freeplay are signs of severe wear, and the tensioner must be substituted. Install the timing belt by sliding the tensioner pulley over the mounting stud, attaching the tensioner washer and retaining nut, but not tightening them fully and then attaching the timing belt and tensioning it. Install the timing belt covers and reconnect the fuel cut-off solenoid wiring to their correct positions. Turn the engine to TDC on No. 1 cylinder, and then take out the timing belt outer covers. Relax the tensioner center nut then turn it counterclockwise to de-tension the timing belt, and then very carefully pull the timing belt over the camshaft sprocket. Keep the camshaft sprocker still and then loosen the retaining bolt; where the proper VW special tool is not available, make a simple home-made tool out of inexpensive materials. Install the home-made tool, next clamp the camshaft sprocket and unscrew and remove the retaining bolt, saving the washer where it is used. Slide the camshaft sprocker off the end of the camshaft and remove the Woodruff key where necessary. Inspect camshaft oil seal to check whether it leaks or not and replace it as needed. Clean the mating surfaces of the sprocket and camshaft. The Woodruff key is installed into the keyway with the plain surface upward facing, followed by the sprocket to the camshaft and the slot on the sprocket fits into the slot on the Woodruff key. Ensure that the engine remains to TDC on cylinder No.1, and install and tension the timing belt and timing belt covers. Install crankshaft drivebelt pulley(s), and place the retaining screws, and then tighten them to the required torque. Install and stress the auxiliary drivebelt(s). Turn the engine to TDC on No. 1 cylinder, and then take out the timing belt outer covers. Relax the tensioner center nut then turn it counterclockwise to de-tension the timing belt, and then very carefully pull the timing belt over the camshaft sprocket. Keep the crankshaft sprocker still, and loosen the fitting bolt; where the correct VW flywheel locking tool is not on hand, clamp the crankshaft in place by removing the starter motor revealing the flywheel ring gear. Insert a stout lever between the teeth of the ring gear and the transaxle bellhousing, slackening the sprocket retaining bolt, which is being done with the help of an assistant. Unscrew the bolt, retrieve the washer and take off the sprocket. Check the crankshaft oil seal, verify whether it is leaking or not and change it accordingly. Wipe off the mating parts between the sprocket and the crankshaft. Install the sprocket again onto the crankshaft, with the lug of the inside of the sprocket fitting into the notch of the end of the crankshaft. Insert the retaining bolt and tighten it to the required torque. Ensure that the engine remains to TDC on cylinder No.1, and install and tension the timing belt and timing belt covers. Install crankshaft drivebelt pulley(s), tension auxiliary drivebelt(s). Disengage the timing belt covers and position the engine to TDC in cylinder number 1. Loose the tensioner center nut and turn it counter clock rotating it off the tension on the timing belt, then carefully reposition the timing belt off the camshaft sprocket. Keep the intermediate shaft sprocker still and loosen the retaining bolt; should no special tool be available on the market which fits the VW, make a home-made tool as has been mentioned before. Installation Place the socket and extension bar to hold the intermediate shaft sprocket, and loosen and remove the retaining bolt and restore the washer where it was placed. Move the sprocket out of the end of the intermediate shaft and retrieve the Woodruff key where it is used. Check the intermediate shaft oil seal and verify whether it is leaking or not and change where required. Wipe the mating parts of the sprocket and shaft. Fit the Woodruff key in the keyway, the plain side upwards and refit the sprocket to the intermediate shaft, fitting the slot in the sprocket to the Woodruff key. Install the retaining bolt of the sprocket to the required torque with the sprocket in the grip of the procedure used during dismantling. Make sure that the engine is still positioned at TDC on No. 1 cylinder, then fit, and tighten the timing belt, and the timing belt covers. Install crankshaft drivebelt pulley(s), tension auxiliary drivebelt(s).
• Idler Pulley
  026-109-243-J
  Q: How to properly immobilize the engine and vehicle before starting work on the Belt Tensioner and Cam Gear on Volkswagen Cabrio?

  A:

  The first step to take before commencing work would be to immobilize the engine and vehicle by removing the cable on the negative terminal of the battery, and it is important to have the right activation code when dealing with any anti-theft stereo system. Put the parking brake on and chock the wheels at the back to ensure it does not move. The components are located under drivebelt(s) and water pump pulley. Start the engine on No. 1 cylinder by turning the engine to TDC and then remove the timing belt upper and lower covers. Loose the retaining nut in the tensioner pulley hub and turn it counterclockwise to take the tension off the timing belt and then take the nut and washer out. Loosen the tensioner off its mounting stud, clean it with no solvents, and look at it. Install the tensioner pulley, washer and retaining nut without tightening, tension the timing belt and install the covers before reconnecting the battery. In the case of the camshaft timing belt sprocker, the timing belt covers are removed, the engine is set to TDC, and the tensioner center nut is loosened, and then the timing belt is slipped off the sprocker. With the retaining bolt loosened, a homemade tool may be needed but hold the sprocket stationary then slide it off and inspect the oil seal to eliminate any leakes. Clean the mating surfaces, fit the Woodruff key (where needed), locate the sprocket and key, check-TD, tension the timing belt and the covers. In the case of the crankshaft timing belt sprocket, the steps to be followed are as follows; that is, to remove the covers, to adjust TDC, and to release tension on the belt. Have sprocket stationary, loosen retaining bolt and then remove sprocket and inspect the seal. Clean the surfaces, install the sprocket, tighten the bolt, check TDC, tension the timing belt and install the covers. In the case of the intermediate shaft sprocket, the covers are to be removed, TDC to be set, tension relieved and the belt removed by sliding it off. Loosen the retaining bolt with a makeshift tool in holding the sprocket, then unscrew the retaining bolt and remove the sprocket checking the oil seal. Cleaning the surfaces, fit the Woodruff key, adjust the sprocket, verify TDC, screw the bolt, tension the timing belt and put the covers on. Lastly, fit and pull the drivebelt(s).