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Discussion Starter #2
Haynes

I'm just going back to my Haynes manual since it is printed in black and white. Haynes wants the camshaft at TDC with the no. 1 cylinder.
 

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Discussion Starter #3
Haynes Says...

On page 2A-7 of the 98-2005 VW New Beetle Haynes Repair Manual it has a figure 5.21 and show the timing belt tensioner properly seated with the tab on the tensioning roller engaged in the hole on the rear timing belt cover. I don't see this hole and I'm just going to put the tab at the top.

Thoughts?
 

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When you check your handy work, the engine will need to be at TDC. You use an opening on the transmission to line up a mark on the flex plate or fly wheel to set TDC.

If you have an automatic trans, here is how to set TDC:

http://newbeetle.org/forums/750427-post1.html

On that page you link to, they have a manual trans where the port you use line up for TDC is at the top of the trans, but the photo shown on that page is worthless because it doesn't show the 2 alignment marks.

Anyway, once you get the belt together, roll the crank over 4 full turns and back to TDC and make sure your cam marks line up and the timing belt tensioner is set correctly as well.

If you've never done a timing belt before and you don't have the Bentley Factory Repair Manual for your car... you're gonna have a bad time.
 

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On page 2A-7 of the 98-2005 VW New Beetle Haynes Repair Manual it has a figure 5.21 and show the timing belt tensioner properly seated with the tab on the tensioning roller engaged in the hole on the rear timing belt cover. I don't see this hole and I'm just going to put the tab at the top.

Thoughts?
There is a hole there for the tensioner. Look and/or feel around for the hole. If you don't get the tensioner properly installed and adjusted correctly, you're asking for trouble. Worst case, the belt will go slack causing gears to jump teeth. If this happens, valves start colliding with pistons causing severe internal engine damage. :(
 

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Discussion Starter #7
Tensioner

I having trouble using the tensioner with my snap ring pliers. Another day shot. :mad:

I'll try tightening the tensioner more to see if that helps.
 

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I bought the special tool for the tensioner from ECS Tuning. Well worth the money for the peace of mind that I had the tension set correctly. If the tension isn't right, the belt could slip or break, which will likely result in severe internal engine damage when you run the engine.

It was a bit tricky holding the tension while turning the ratchet to attach the tensioner to the engine. I'm sure it's possible to do this without the special tool, but the tool certainly helped.
 

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Just finished a timing belt, new valve cover gasket, and a pre cat O2 sensor today. The hole for the tensioner is near 12 o'clock. The back of the tensioner will sit flush with the block when you have it right. Use the flywheel TDC mark for crankshaft alignment. The hub on the crank can move. You can view it from in front of the car if you look from right above the radiator to the right of the coil pack. Half the dot should be on the lower part of the window with the other half starting to disappear if you roll the crank bolt clockwise toward the front of the car. My crankshaft hub had moved. The flywheel mark will not slip. Just my own observations hope it helps.
 

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Discussion Starter #10
I Found It!

I located the notch on the rear timing belt cover.

Now I'm having difficulty using the snap ring pliers I have to maneuver the tensioner to slip the belt on. But as the old saying goes, "If all else fails, read the instructions." Haynes says to put the belt "over the idler pulley, water pump and the camshaft sprocket. Ensure the belt teeth seat correctly on the sprockets, then install the belt around the timing belt tensioner."

Anyone use a snap ring pliers with any luck?
 

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To the op; this isn't going to end well. If you do not do this correctly you will eventually end up with a damaged engine and a large repair bill. You may be saving a few bucks now but not in the long run. First off the haynes manual is crap. Get a Bentley. Then you are not using the correct tools nor does it seem you really have a grasp of what needs to be done. The 2.0 is a relatively simple belt especially when compared to the 1.9 tdi. In your case I strongly suggest you take it to a shop that knows what they are doing to at least check over the work. I do not know your location so I cannot recommend anyone.

As far as the write up from tom goes, first off you need to clean the area after w-pump replacement, not just wipe it. Brake cleaner and air pressure work well for that, then wipe it just to be sure. Next, do NOT put nail polish on a brand new belt. Use the timing mark for TDC on the flywheel. Your cam sprocket already has a mark. I didn't notice if it was recommended to change out the bolts. If not you should. Everything needs to be properly torqued with a decent torque wrench. Otherwise it was a decent guide.
 

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mike03 2.0 vert
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In the middle of the water pump

Just came accross this particular THREAD. I have been watching u-tube videos and reading so many pages of my Bentleys. Also found the auto transmission hole and see a blue thing in the opening. All day yesterday struggling and
working between raindrops. I stopped last evening just ready to remove the belt. Well this paint and match really does add to the overall how to, and Tom, ITS GREAT. BIG THANKS.
 

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Discussion Starter #15
Finally

I looked at the PDF and did install the timing belt. The trick is to not put the nut and washer on the tensioner before the belt is on. Nothing else pointed that out besides the PDF.

Now, I just have to tension it and reinstall everything and I am back in business.
 

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Discussion Starter #16
Coincidence?

I just looked at the mail from yesterday and included was a letter for MyVWInsurance which includes "towing to your nearest VW dealer."

Asteroid 4179 Toutatis is about to pass by the Earth. Don't Beetle owners like to congregate in some desert area to commemorate an outer space event?
 

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Discussion Starter #19
The PDF Says...

He only rotates the engine twice by hand. Wouldn't four times be accurate to get it on the same stroke?
 

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mike03 2.0 vert
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turns

Turning the crank twice is once on the valves. Turning four times will not give a different answer, just the same answer again.;) I did like his video, was your take on his work ok? Between the video and "Indytoms how to" with markers, I settled down enough to feel comfortable doing the water pump and belt.
 
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