Question about 2003 Volkswagen Jetta TDI

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Alternator belt/pulley diagram for 1992 diesel volkswagen golf.

I am trying to fit a new alternator belt to my mark 3 turbo diesel golf, and cannot get the tensioner to take up the tension, is there something that I am doing wrong, I would like to see a diagram.

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  • shelleyrick Feb 04, 2009

    Can't see a diagram on the car, or in the Haynes manual.

  • JeremyBeats May 11, 2010

    Are you sure the belt is the right size? That happened to me. Took me awhile of fiddling till I realized it was just an inch or so too long.

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Is there a diagram on under the hood or on top of the plate over the radiator ?

Posted on Feb 03, 2009

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How to change altenater belt on 87' cabi



INSPECTION

Inspect the belts for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately. It is always best to replace all drive belts at one time, as a preventive maintenance measure, during this service operation.


CHECKING TENSION AND ADJUSTMENT

See Figure 1
The belt tension on most driven components is adjusted by moving the component (alternator, power steering pump etc.) within the range of a slotted bracket. Some brackets (toothed) use a rack and pinion mechanism which moves the alternator side-to-side to adjust the belt tension. With this configuration, no prying tools are required. On Quantum (except 5 cylinder) and Fox models, the air conditioner compressor drive belts are adjusted by varying the number of discs (shims) between the halves of the crankshaft pulley. Before adjusting the belt tension on any engine, look at the mounting and determine what kind of bracket is used.
To check belt tension, push in on the drive belt about midway between the crankshaft pulley and the driven component. If the belt is less than 39.4 in. (1m) long, it should deflect between 0.80-0.120 in. (2-5mm). For longer belts, it should deflect between 0.40-0.060 in. (10-15mm). Belt size is usually printed on the back side of the belt. If it can't be read, it's probably time to replace it.


0900c1528026638b.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 1: To check belt tension, push in on the drive belt about midway between the crankshaft pulley and the driven component
Slotted Brackets
See Figures 2, 3 and 4

  1. Loosen the adjustment nut/bolt in the slotted bracket. Slightly loosen the pivot bolt.
  2. Pull (don't pry) the component outward to increase tension. Push inward to reduce tension. Tighten the adjusting nut/bolt and the pivot bolt.



0900c1528026638c.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 2: Alternator mounting with slotted brackets

  1. Components, such as the power steering pump and some air conditioner compressors, may be mounted with a double slotted adjusting bracket using a threaded bolt and locknut to adjust and maintain tension. Loosen the locknut(s) and slightly loosen the bolt(s) in the slotted groove(s). Turn the threaded adjustment bolt(s) in or out to gain correct tension. Tighten locknut(s) and slotted bracket bolt(s).
  2. Recheck the drive belt tension, readjust if necessary.



0900c1528026638d.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 3: Some components use a double slotted adjusting bracket with a threaded bolt and locknut to adjust and maintain tension. Loosen the locknut (shown) before adjusting the tension bolt


0900c1528026638e.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 4: An extension is helpful when adjusting the tension bolt. Be sure to loosen the nut/bolt on the rear slotted bracket first
Toothed Brackets
See Figures 5 and 6

  1. Loosen the tension bolt and the alternator pivot bolt. These bolts should be loosened until the alternator swings freely under its own weight.



0900c1528026638f.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 5: Loosen the tension bolt (shown) and the alternator pivot bolt until the alternator swings freely under its own weight

  1. Adjust the V-belt by turning the nut on the tension bolt while checking the belt deflection with your thumb.
  2. Once the proper tension is achieved, tighten the tension bolt to 26 ft. lbs. (35 Nm). Tighten the pivot bolt to 15 ft. lbs. (20 Nm).
  3. Recheck the drive belt tension, readjust if necessary.



0900c15280266390.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 6: Adjust the V-belt by turning the nut on the tension bolt
Split Pulley
See Figure 7
On Quantum (except 5 cylinder) and Fox models, the air conditioner compressor drive belts are adjusted by varying the number of discs (shims) between the halves of the crankshaft pulley.

  1. Remove the nuts/bolts securing the tensioner plate and crankshaft pulley halves.
  2. Add or remove the amount of spacer discs between the pulley halves until the belt tension is correct.



0900c15280266391.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 7: Belt adjusting shims on Quantum (except 5 cylinder) and Fox models. Extra shims are stored behind the tensioner plate on Fox and turbo diesel Quantums (shown)
If there are any shims left over, do not throw them away. On Fox and turbo diesel Quantum models, store the extra shims in front of the split pulley (behind the tensioner plate). On Quantums with 4 cylinder gas engines, store the extra shims behind the split pulley (in front of the crankshaft hub).

  1. Secure the pulley halves. Torque the pulley nuts or bolts to 15 ft. lbs. (20 Nm).


REMOVAL & INSTALLATION

If a belt must be replaced, the driven unit must be loosened and moved to its extreme loosest position (usually by moving it toward the center of the motor). After removing the old belt, check the pulleys for dirt or built-up material which could affect belt contact. Carefully install the new belt, it may appear to be just a little too small to fit over the pulley flanges. Fit the belt over the largest pulley (usually the crankshaft pulley at the bottom center of the motor) first, then work on the smaller one(s). Gentle pressure in the direction of rotation is helpful. Some belts run around a third or idler pulley, which acts as an additional pivot in the belt's path. It may be possible to loosen the idler pulley as well as the main component, making your job much easier. Depending on which belt(s) you are changing, it may be necessary to loosen or remove other interfering belts to get at the one(s) you want. Some models have a front engine mount installed through the air conditioner compressor belt circle. Support the engine and remove the mount prior to belt removal and installation.
When buying replacement belts, remember that the fit is critical according to the length of the belt, the width of the belt, the depth of the belt and the angle or profile of the V shape (always match up old belt with new belt if possible). The belt shape should exactly match the shape of the pulley; belts that are not an exact match can cause noise, slippage and premature failure.
After the new belt is installed, adjust it for proper tension. This is sometimes a three or four-handed job; you may find an assistant helpful. Make sure that all the bolts you loosened are retightened and that any other loosened belts also have the correct tension. A new belt can be expected to stretch a bit after installation so be prepared to re-adjust your new belt.
After installing a new belt, run the engine for about 5 minutes and then recheck the belt tension.

May 19, 2012 | 1987 Volkswagen Cabriolet

1 Answer

Timing marks trooper 1985 mod dlx turbo diesel


Refer to Figures 1,2,3,4 when performing 17-step timing procedure for 1981-1985 Diesel Engines.

Fig 1. Injection pump and camshaft alignment marks - Diesel engine.

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Fig 2. Removing the timing belt holder - Diesel engine.

archaeology_67.jpg

Fig 3. Injection pump alignment marks - Diesel engine.

archaeology_68.jpg

Fig 4. Tensioiner Pulley Bolt Sequence - Diesel engine.

archaeology_69.jpg

Procedure - Timing Belt replacement.

1. Disconnect the negative battery cable. Drain the cooling system.

CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2. Remove the timing belt cover. Remove the injection pump sprocket flange.

3. Using a prybar, remove the tension spring from the timing belt tensioner.

When removing the tension spring, avoid using excessive force for the spring may become distorted.

4. Remove the tensioner pulley bolt and the pulley.

5. Remove the timing belt and discard it.

To install:

6. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.

7. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.

8. Using a new timing belt, install it in the following sequence: crankshaft sprocket, camshaft sprocket and the injection pump sprocket; the slack must be between the injection pump and camshaft sprockets.

9. Install the tension center and the tension pulley so the end of the tension center is fitted against both pins on the timing pulley housing.

10. Hand tighten the nut so the tension pulley can be rotated freely.

11. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (30-48 Nm).

12. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.

13. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-128 Nm).

14. Install the injection pump sprocket flange; the hole in the outer circumference of the flange should be aligned with the triangular timing mark on the injection pump sprocket.

15. Rotate the crankshaft 2 full turns clockwise to bring the No. 1 piston to TDC of the compression stroke. Make sure the triangular timing mark on the timing sprocket is aligned with the hole in the flange, then, measure the timing belt tension; it should be 33-55 lbs.

16. Install the timing belt cover.

17. Connect the negative battery cable.

Jul 04, 2011 | 1995 Isuzu Trooper

1 Answer

How do I change the alternator belt on my1990 vw diesel jetta


as the alternator IS the adjuster for the tension of the belt,it is a simple task of undoing the alternator bolts/nuts and pushing it inwards to fit belt,then pull it outward to tension belt to correct tension...

Aug 14, 2010 | 1990 Volkswagen Jetta

2 Answers

Hi we have a kia sedona 2000year and 2.9 diesel, exec. auto. it came with half the engine in the boot, we have skimed the head and rebuilt it just the new cam belt just wont tighten enough we have fully...


the cam belt should have a little slack in it,, about 1/2 inch over its longest run, its not like a fan belt witch should be tight, but check the idler bearing are not worn out,,and i do hope this is a new belt for this car,,,if your using the old belt,,,dont! fit a new one on it or it could brake on you, and that would be another engine rebuild on your hands,,,
,

Mar 07, 2010 | 2003 Kia Sedona

1 Answer

Drive belt assembly


The mark II VW uses one large belt which goes around the crank, water pump and A/C compressor. Then, there is another smaller belt that goes around the crank and power steering pump (if equipped). Then, a smaller belt goes around the A/C compressor and around the alternator. If it's a diesel, there will also be a tensioner pulley for the alternator belt. If gasoline, there will be no pulley. To answer your question, there are 3 belts. One big one and two small ones.

Jul 07, 2009 | 1986 Volkswagen Golf

2 Answers

Cambelt change on uno turbo


By now you probably have the cam/timing belt changed on the vehicle... Here goes anyway: I changed the belt on my 1372cc (identical engine - except for the Turbo and a few odds & ends) just over a week ago by following this simple process:

Disconnect the battery negative terminal
Remove the timing belt cover
Loosen the alternator drive belt nut, tilt towards engine and remove the belt
Remove the crankshaft pulley nut (size 36) - do this by selecting top gear and have an assistant press hard on the brake pedal - remove the pulley -the timing belt is now exposed.
Using paint or tippex, simply mark the camshaft sprocket as it lies with the inside timing belt cover, do the same on the crankshaft sprocket & the auxiliary shaft sprocket.
Loosen the tensioner nut - remove the timing belt.
Check that all pulleys are still in alignment according to your markings and refit the new belt by starting on the crankshaft sprocket (the thin white line across the new belt must align with the factory marking on the crankshaft pulley) and over the auxiliary sprocket and finally over the camshaft sprocket - tension the belt with the tensioner and tighten the tensioner nut.
Rotate the engine clockwise by hand making sure the camshaft sprocket rotates twice, check the tension on the belt and make sure the tensioner nut is fully tightened and the belt is secure.
Refit the crankshaft pulley, making sure the nut is tightened and refit the alternator belt, timing cover and reconnect the battery.

The same procedure is applicable on the 999cc/1108cc FIRE models as well as the 1301cc Turbo.

Good luck.


Apr 14, 2009 | Fiat 124 Cars & Trucks

1 Answer

My car is a VW golf Gti mk3 8v 2.0L, Alternator / water pump drive belt has snapped and been lost. I have new belt but I'm unsure of routing around the 3 pulleys. does the alternator act as the tensioner??


loosen the alternator and push the alternator to-wards the engine,put your new belt on ,fitting around the 3 pulleys once fitted look and see that the belt is in line.If your happy the belt is lined put a small bar between the engine and alternator and force the alternator out towards the front this should tension your belt tighten bolts on alternator.;at the longest point between two pullys in the middle of the belt move belt up and down with fingers if tension is right it should not move more than about 150ml,hope this helps you.adrian

Feb 02, 2009 | 1997 Volkswagen Golf

1 Answer

Alternator belt


Hi

Either you have a siezed or partially siezed idler pulley, tensioner pulley, or ancilliary device (alternator, PAS pump, aircon compressor, etc), a weak tensioner spring on the auto tensioner, or the belt is running out of true.

Or

There is a bolt or something similar protruding into the area of the belt and wearing its way through it.

Regards

Geordie

Aug 08, 2008 | 1999 Volkswagen Golf

1 Answer

2004 F250 Turbo Diesel alternator pulley


the belt tensioner is on the lower left of the engine there is a 1/2 drive square hole on the right hand side pulley arm to release the tension its a pain to get at but you can, sometimes it is easier from the bottom

Jul 31, 2008 | 2004 Ford F250

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