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Chad Farhat
Chad Farhat, ASE Certified Technician A6 - Electrical / Electronic systems A7 Heating / Air conditioning systems
Category: VW
Satisfied Customers: 1533
Experience:  Owner at Carolina Auto Service & Sales , 20 years Experience in Foreign& Domestic vehicles
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2004 Volkswagen jetta 1.8L turbo...on the timing...theres a

Customer Question

2004 Volkswagen jetta 1.8L turbo...on the timing...theres a timing tensioner pulley and a timing dampener...the issue I'm having is ive got excessive slack in my belt and an awful clattering noise from the belt slapping the cover...how could I diagnose which part to replace and how to replace them? theres not much room to work on either part...
Submitted: 5 months ago.
Category: VW
Expert:  Chad Farhat replied 5 months ago.

Hi my name is ***** ***** I will be assisting you today

Expert:  Chad Farhat replied 5 months ago.

give me few minutes let look it up for you

Expert:  Chad Farhat replied 5 months ago.

this what you asked for

I dont know your skill level but this is job i skill level A and it call s for 1.9 hrs but probably will take 4 hrs with proper equipment

But here you go , Make sure you follow timing marks and take picture of everything before you take off if you end up doing it

Vehicle » Timing Belt » Parts and Labor

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2004 Volkswagen Jetta Sedan (9M2) L4-1.8L Turbo (AWP)

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Parts InformationOEM Part #Price

Timing Belt

15 - Timing Belt

06B109119A$65.00

Labor InformationSkill LevelMfg. WarrantyStandard

Replace

B1.93.7

© 2016 ALLDATA, LLC. All Rights Reserved. Terms of Use (Version 2.0.13792)

I dont know your sakill level but this is

Vehicle » Timing Components » Timing Belt » Service and Repair » Procedures » Checking Toothed Belt For Camshaft

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2004 Volkswagen Jetta Sedan (9M2) L4-1.8L Turbo (AWP)

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Toothed Belt, Checking condition

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Open fasteners of upper toothed belt cover and remove cover.
Check condition of toothed belt for:
Cracks, cross-sectional breaks
Separation (cover layer, belt cords)
Wear-through on cover layer
Fraying of cord strands
Surface cracks (plastic shroud)
Traces of oil and grease

Note: It is essential to replace toothed belt if malfunctions are found. This will avoid possible break-downs or operating problems. Replacing the belt is a repair procedure.

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While checking the condition, take notice of the following defects:
A - Tears (cover side)
B - Lateral movement
C - Fraying
D - Tears (in teeth)

See also "Timing Belt Replacement, Important Note". See: Maintenance > Service Intervals

Vehicle » Engine, Cooling and Exhaust » Engine » Timing Components » Timing Belt » Service and Repair » Removal and Replacement » Removal and Installation

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2004 Volkswagen Jetta Sedan (9M2) L4-1.8L Turbo (AWP)

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Toothed belts, removing, installing and tensioning

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Special tools and equipment

- 10-222A Engine support bracket with legs 10222A11
- 3180 Retainer (for turbocharged engines)
- T10092 Tensioning bolt
- T40011 Locking pin
- VAG 1331 Torque wrench (5 to 50 Nm)
- VAG 1332 Torque wrench (40 to 200 Nm)
- D 000 600 A2 Locking fluid

Removing

- Note safety precautions before starting work.
- Observe rules for cleanliness.
- Remove engine cover.
- Remove insulation tray, refer to Body and Frame - Sound Proofing/Insulation - Service and Repair - Procedures See: Sound Proofing / Insulation > Procedures
- Remove right-hand headlight, refer to Lighting and Horns - Headlamp - Service and Repair - Procedures See: Headlamp > Procedures
- Remove intake pipe between turbocharger and charge air cooler, refer to Powertrain Management - Fuel Delivery and Air Induction - Turbocharger - Service and Repair - Procedures See: Turbocharger > Procedures
- Remove ribbed belt, refer to Engine - Drive Belts, Mounts, Brackets and Accessories - Drive Belt - Service and Repair - Procedures See: Drive Belt > Removal and Replacement
- Remove tensioning element for ribbed belt.

Engine installed:

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- Turn crankshaft to TDC No. 1 cylinder (vehicles with manual transmission).

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- Turn crankshaft to TDC No. 1 cylinder (vehicles with automatic transmission).

Engine removed:

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- Turn vibration damper to TDC No. 1 cylinder-arrows-.
- Remove coolant expansion tank and place to side.
- Remove power assisted steering reservoir and place to side.
- Pull off vacuum pipes at activated charcoal filter and at throttle valve housing.
- Remove toothed belt guard-upper part.

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- Install engine support bracket 10222A with legs 10-222A/1.
- Locate bracket 3180 in lifting eye on cylinder head and take-up weight of engine.

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- Remove securing bolts from assembly mount/engine mount, assembly mount/body and assembly mount/body mount-arrows-and remove assembly mount complete.
- Remove engine mount on cylinder block.

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- Remove vibration damper/belt pulley.
- Remove lower and center toothed belt guard.
- Mark direction of rotation of toothed belt.

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- Screw tensioning bolt T10092 into toothed belt tensioning element.
- Align pressure piston using pointed pliers or wire before tensioning (hole in pressure piston must align with hole in housing).
- Tension piston of tensioning element just enough that the piston can be locked with locking pin T40011.
- Remove toothed belt.
- Turn crankshaft back slightly.

Installing

Note: When turning the camshaft crankshaft must not be at TDC. Danger of damage valves/piston crown.

A - Toothed belt completely removed
If toothed belt has only been removed from camshaft, skip down to B - Toothed belt only taken off camshaft sprocket

Conditions
The pistons must not be positioned at TDC.

Work sequence

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- Bring mark on camshaft in line with the mark on cylinder head cover.
- Place toothed belt on crankshaft sprocket (observe direction of rotation).
- Install engine mount to cylinder block. Tightening torque: 45 Nm

Note: Before installing engine mount insert bolts into mount.

- Install lower part of toothed belt guard. (Insert securing bolts with locking fluid "D 000 600 A2".) Tightening torque: 10 Nm
- Secure vibration damper/belt pulley with one bolt (note arrangement).

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- Turn crankshaft to TDC No. 1 cylinder.
- Install toothed belt onto coolant pump, tensioning roller and camshaft sprocket.
- Tension toothed belt

B-Toothed belt only taken off camshaft sprocket

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- Bring mark on camshaft in line with the mark on cylinder head cover.
- Turn crankshaft to TDC No. 1 cylinder.
- Install toothed belt onto camshaft sprocket.
- Tension toothed belt.

Tensioning toothed belt

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- Tension toothed belt by pulling out locking pin T40011 and removing tensioning bolt T10092.
- Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference points.
- Install vibration damper/belt pulley tightening torque: 25 Nm
- Install center part of toothed belt guard. (Insert securing bolts with locking fluid "D 000 600 A2".) Tightening torque: 10 Nm
- Install upper toothed belt guard.
- Install engine assembly mount, refer to Engine - Drive Belts, Mounts, Brackets and Accessories - Engine Mount - Service and Repair - Procedures
- Install ribbed belt tensioner. Tightening torque: 25 Nm
- Install ribbed belt, refer to Engine - Drive Belts, Mounts, Brackets and Accessories - Drive Belt - Service and Repair - Procedures See: Drive Belt > Removal and Replacement

Hope I was helpfull to you

A Positive rating is Much Appreciated

This Post Will Stay Open Even after You Rate Me For You To Come Back And Ask Me Anything Follow Up Questions You May have OnThis Issue.

Thank You

Chad Farhat ( aka -Customer )
ASE Certified Technician

Expert:  Chad Farhat replied 5 months ago.

the rest of the diagrams

good luck

Expert:  Chad Farhat replied 5 months ago.

the slapping belt is caused by a failed tensioner for the timing belt

Expert:  Chad Farhat replied 5 months ago.

it will help if you had this tool too

Expert:  Chad Farhat replied 5 months ago.

no sorry you dont need that tool that is for v6 , disregard the last picture

Customer: replied 5 months ago.
Wow. I am skilled and could probably do this, but I think I may get this done at a shop if it doesn't cost too much..thank u for ur time.
Expert:  Chad Farhat replied 5 months ago.

you welcome anytime

please dont forget to rate me since that is how we get compensated

if you like my assistance next time you post a question just start your question with ( FOR CHAD ORCustomerONLY )

and I will see it or you can request me thru customer service by email them

Good luck

Expert:  Chad Farhat replied 5 months ago.

I dont blame you , i m skilled to but this particular job on this car is not my favorite :) it is so tight in there .

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