testarossaguy

I've ordered the Blau kit for my lovely girlfriend's 2002 Beetle, and I "think" I can do this job okay. But having a little more information would be a comfort to me. I recently did the belt service on my A8L without problems, and I do the timing belts (2) on my Testarossa during the engine-out service (peformed 3 so far). I've searched the archives for specific information but couldn't find it. I will gladly compensate someone if they will be kind enough to supply me with the prodecure for this job. Thank You Everyone.

ex-a8drifter

There's nothing on VW Vortex? Go search there...I did a quick one..lots of topics, no time to brows

JimR

Also ask in B7 A4.

vertigobora

It's not the same as the procedure for the B7 Audi A4.

I've done belts for the MK3 and MK4 2.0s, but never on a Beetle itself. However, the engines in the MK4s are identical to the MK3. Here's a guide to doing it on a MK3, should be VERY similar if not identical. (Keep in mind this in not a guide and in no way makes the author liable if it goes wrong)

1.) List car and remove front passenger side wheel, don't forget jackstands. Remove the splash guard. Disconnect negative battery terminal.

2.) Loosen the tensioner behind the alternator to remove the accessory bent. If you like, you can remove the alternator for more room, but I just left it in.

Here's a pic of the tensioner on a MK3, it's similar to the MK4/Beetle. <img src="http://www.vwenthusiast.com/technical/TimingBelt/RemoveAirbox.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket">

3.) Now, using the 3/4" Socket, rotate the engine clockwise until all the TDC (top dead center) marks line up. On the cam gear you will see an OT mark as well as an OT mark on the engine block. The lower pulley has a notch in it to line up with the lower cover piece you haven't removed yet. Using your impact wrench, remove the bolt from the lower pulley, and then pull off the pulley. **Note: First try removing the allen head bolts (either 5mm or 8mm, I can't remember). With these off you do not need to remove the entire pulley. In the case of this car, those wouldn't budge, but I was able to remove the crank bolt. Wierd, huh?

4.) Next, using your 1/2" socket, 10mm Socket and Allen Wrenches, remove the bolts holding the lower belt cover on, and remove. Then using the 13mm box wrench, loosen the bolt on the timing belt tensioner and release tension to the belt. Now you can remove your old timing belt. Next you will see the distributor gear. This gear also has an OT mark on it, but don't use this one! Pull the distributor cap off and look for a notch in the housing that points roughly straight back. Make sure the rotor is pointing at this mark. Next, install your new timing belt, and replace the lower cover.

Here's some pictures from the Bentley manual to help ya out.

<img src="http://www.vwenthusiast.com/technical/TimingBelt/BentlyFig1.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket">

<img src="http://www.vwenthusiast.com/technical/TimingBelt/BentlyFig2.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket">


<img src="http://www.vwenthusiast.com/technical/TimingBelt/BentlyExploded.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket">

P.S. I highly recommend replacing the accessory belt when doing the timing belt. It's not really a big deal, it's just one of those "while you're in there" things. Hope this helps!

-Alex