Hi, could you please tell how to remove the bottom cover on a 1.6 vw bora......which is covering the bottom pulley for a timing belt change..... does the tensioner need to come off.....? and if so how do you remove this...... Many thanks, Steve

Hi, I have pasted instructions below from autozone.com. The instructions call for the use of special tools. You can improvise with alternate tools, but please make sure your timing is right before closing the cover. Please let me know if you have questions, and thanks for using FixYa.

1.9L Diesel Engine
Some special tools are required to perform this procedure properly. A flat bar, VW tool 2065A is used to secure the camshaft in position. A pin, VW tool 2064 is used to fix the pump position while the timing belt is removed. The camshaft and pump work against spring pressure and will move out of position when the timing belt is removed. It is not difficult to find substitutes but do not remove the timing belt without these tools.

WARNING Do not turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.

1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s). Remove the camshaft cover and rubber plug at the back end of the camshaft.
2. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner timing belt cover or the edge of the cylinder head.
3. With the engine at TDC, insert the bar into the slot at the back of the camshaft. The bar rests on the cylinder head to will hold the camshaft in position.
4. Insert the pin into the injection pump drive sprocket to hold the pump in position.
5. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt. Slide the timing belt from the sprockets.
   
   
   

   Fig. Use the VW tool to lock the camshaft at TDC for timing belt replacement-Volkswagen 1.9L Diesel engines
   
   
   
   

   Fig. Locking the injection pump with the VW tool as shown-Volkswagen 1.9L Diesel engines
   

To install:

1. Install the new timing belt and adjust the tension so the belt can be twisted 45 degrees at the halfway point between the camshaft and pump sprockets. Tighten the tensioner nut to 33 ft. lbs. (45 Nm).
2. Remove the holding tools.
3. Turn the engine 2 full revolutions to return to TDC for the No. 1 cylinder. Recheck belt tension and timing mark alignment, readjust as required.
4. Install the belt cover and accessory drive belts.
   NOTE If the belt is too tight, there will be a growling noise that rises and falls with engine speed.

Hi, the crankshaft marks are on the belt pulley and timing cover, so you have to mate it up to see them. The cam sprocket mark goes on the bottom, and aligns with another mark on the timing cover. There is a plug you pull out and hole to look thru to align the cam sprocket/shaft.








Rotate the engine so that No. 1 cylinder is at TDC on the compression stroke. Check that the timing marks are aligned on the camshaft and crankshaft pulleys. An access plug is provided in the cam belt cover so that the camshaft timing can be checked without removal of the cover or any other parts. Set the crankshaft to TDC by aligning the timing mark on the crank pulley with the TDC mark on the belt cover. Look through the access hole in the belt cover to make sure that the timing mark on the cam drive sprocket is lined up with the pointer on the inner belt cover.

I found a 2.0L VW engine for a Cabrio. Not sure if this is the right one, but here goes:

REMOVAL & INSTALLATION

NOTE: Do not turn the engine or camshaft with the timing belt
removed. The pistons will contact the valves and cause internal engine damage.

Gasoline Engines






Fig. 1: Adjusting the belt tension on a 2.0L 8 valve








Fig. 2: Remove the timing belt cover








Fig. 3: Align the timing marks








Fig. 4: Locate the tensioner








Fig. 5: Loosen the tensioner bolt








Fig. 6: Mark the belts direction of rotation

1. Disconnect the negative battery cable and remove the accessory drive belts,
   crankshaft pulley and the timing belt cover(s).
   
2. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to
   TDC of No. 1 piston. The mark on the camshaft sprocket should be aligned with
   the mark on the inner timing belt cover or the edge of the cylinder head.
   
3. With the distributor cap removed, the rotor should be pointing toward the
   No. 1 mark on the rim of the distributor housing. On 8 valve engines, the notch
   on the crankshaft pulley should align with the dot on the intermediate shaft
   sprocket.
   
4. Loosen the locknut on the tensioner pulley and turn the tensioner
   counterclockwise to relieve the tension on the timing belt.
   
5. Slide the timing belt from the sprockets.
   To install:
   
   
6. Check the alignment of the timing marks. On 16 valve engines, the mark on
   the tooth should align with the mark on the rear belt cover.
   
7. Install the new timing belt and tension the belt so it can be twisted 90°at
   the middle of it's longest section, between the camshaft and intermediate
   sprockets.
   
8. Recheck the alignment of the timing marks and, if correct, turn the engine 2
   full revolutions to return to TDC of No. 1 piston. Recheck belt tension and
   timing marks. Readjust as required. Torque the tensioner nut to 33 ft. lbs. (45
   Nm).
   
9. Install the belt cover and accessory drive belts.
   
10. If the belt is too tight, there will be a growling noise that rises and
    falls with engine speed.

Diesel Engines

Some special tools are required. A flat bar, VW tool no. 2065A, is used to
secure the camshaft in position. A pin, VW tool no. 2064, is used to fix the
pump position while the timing belt is removed. The camshaft and pump work
against spring pressure and will move out of position when the timing belt is
removed. It is not difficult to find substitutes but do not remove the timing
belt without these tools.
NOTE: Do not turn the engine or camshaft with the timing belt
removed. The pistons will contact the valves and cause internal engine damage.

1. Disconnect the negative battery cable and remove the accessory drive belts,
   crankshaft pulley and the timing belt cover(s). Remove the camshaft cover and
   rubber plug at the back end of the camshaft.
   
2. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to
   TDC of No. 1 piston. The mark on the camshaft sprocket should be aligned with
   the mark on the inner timing belt cover or the edge of the cylinder head.
   
3. With the engine at TDC, insert the bar into the slot at the back of the
   camshaft. The bar rests on the cylinder head to will hold the camshaft in
   position.
   
4. Insert the pin into the injection pump drive sprocket to hold the pump in
   position.
   
5. Loosen the locknut on the tensioner pulley and turn the tensioner
   counterclockwise to relieve the tension on the timing belt. Slide the timing
   belt from the sprockets.
   To install:
   
   
6. Install the new timing belt and adjust the tension so the belt can be
   twisted 45 degrees at a point between the camshaft and pump sprockets. Torque
   the tensioner nut to 33 ft. (45 Nm).
   
7. Remove the holding tools.
   
8. Turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck
   belt tension and timing mark alignment, readjust as required.
   
9. Install the belt cover and accessory drive belts.
   
10. If the belt is too tight, there will be a growling noise that rises and
    falls with engine speed.

Here are the instructions for removing the timing cover, and for replacing the timing belt. If this is helpful, please click my accept button! Thanks!
Remove accessory drive belts.

1. Remove water pump pulley to pump hub attaching bolts, then the pulley.
2. Remove right inner fender panel to gain access to crankshaft pulley.
3. Remove outer crankshaft pulley attaching bolts, then the outer stiffener/spacer and outer pulley
4. Remove inner stiffener/spacer, attaching screws, inner pulley and baffle plate.
5. Remove attaching bolts, then the upper and lower timing covers.
6. Reverse procedure to install. When installing crankshaft pulley, ensure curved lip on baffle plate and deep recess of inner pulley face outward

1. Remove timing belt covers as outlined previously.
2. Remove timing belt tensioner pulley attaching bolt, then the tensioner pulley, spring and spring cover
3. If reusing old belt, mark direction of rotation on belt to aid installation.
4. Remove timing belt from crankshaft and camshaft sprockets.
5. Check crankshaft and camshaft sprockets, tensioner pulley and timing belt for wear or damage. Replace components as necessary.
6. Align camshaft and crankshaft sprocket timing marks with marks on cylinder head and oil pump housing
7. Install timing belt. If reusing old belt, ensure belt is installed so that direction of rotation mark made during removal is positioned correctly.
8. Install spring and spring cover onto tensioner pulley, then install pulley and attaching bolt. Do not tighten bolt at this time.
9. Install tensioner spring onto anchor, then tighten pulley attaching bolt to torque listed at the end of this section.
10. Reinstall timing belt covers.

This photo shows timing marks.

Hi,


You find the timing marks on the picture below.





Removal
Remove auxiliary 1. drive belts.
2. Support engine.
Remove:
Engine mounting and bracket.
Timing belt upper cover [1].
3.
4. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [2] & [3].
Remove:
Crankshaft pulley bolt [4].
Crankshaft pulley [5]. Use tool No.09213-60017.
5.
6. Ensure timing marks aligned [2] & [3].
7. Slacken tensioner bolt [6]. Move tensioner away from belt and lightly tighten bolt.
Remove:
Timing belt lower cover [7].
Crankshaft sprocket guide washer [9].
Timing belt.
Tensioner pulley.

Installation
Installation
1. Check tensioner pulley for smooth operation.
2. Check free length of tensioner spring is 46,0 mm [8]. Replace spring if necessary.
3. Fit tensioner and spring. Ensure spring is connected correctly.
4. tighten bolt [6].
5. Ensure timing marks aligned [2] & [3].
6. Fit timing belt. Ensure belt is taut between sprockets.
Install:
Crankshaft sprocket guide washer [9].
Timing belt lower cover [7].
Crankshaft pulley [5].
7.
8. Slacken tensioner bolt 1/2 turn [6].
9. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [2] & [3].
Turn crankshaft slowly 1 7/8 turns clockwise until crankshaft pulley timing mark [3] aligned with 45° BTDC mark [10] on
timing belt lower cover [7].
10.
11. Tighten tensioner bolt [6]. Tightening torque: 42 Nm.
12. Install components in reverse order of removal.
13. Tighten crankshaft pulley bolt [4]. Tightening torque: 108 Nm.
Manufacturer: Toyota

What is needed Tools: 6mm and 8mm allen wrench socket, 5mm allen wrench. 8mm, 13mm, 19mm socket and ratchet. 10mm combination wrench. Long ratchet extensions (at least one 6in, more are helpful). 5inch Wheel puller (for main shaft pulley). (Some models may need a special spanner tool to adjust the timing belt tensioner) Parts: 2 gal of anti-freeze mixed with distilled water. All three V-belts. (Alt, A/C, P/S) $32.95 New water pump top. $91.91 New gasket for WP. $9.13 New timing belt. $26.13.


Procedure:

Remove battery cable (either power (+) or ground (-)) remove alternator remove A/C remove power steering pump .Remove water pump pulleys remove main shaft pulleys remove timing belt covers remove A/C mounting hardware remove timing belt (don't turn any of the wheels its connected to) replace timing belt adjust belt tension remove water pump face put on new gasket and new part.

Leave pulleys off. replace bottom timing belt cover, replace crank shaft pulley, replace steering pump, replace A/C, put small belt on A/C (hang loose) put large belt around A/C, Main and water pump pulley. put middle size belt on Main water pump and power steering pump reattach bolts for the steering pump pulleys put alternator back on adjust all belts. connect battery

Problem areas:
Main pulley: There are 4 6mm hex head bolts. These must be removed. The main 19mm hex head can be used to turn the engine it the timing belt slips and you have to readjust the timing.

Putting on new belts: This can be a real pain if you get VW belts. The adjustments won't give enough to put the belts over the edge so the easy way is to remove the pulley on the water pump. Then its real easy.

Timing: If you turn the wheels that the timing belt goes on you will have to reset the timing. Mark the timing points with something like whiteout so its easy to see. The timing mark on the toothed gears are small dots. The timing mark for the crankshaft is a small cut on the outer pulley. When its aligned with the intermediate wheel timing mark (there is an arrow on the cover as a hint) should intersect as viewed from the right wheel well. The camshaft timing mark should line up with the top of the engine near the front.

Power steering pump: It is held on with lots of bolts. One is in a channel that is hard to see but can be found with a 6" extension. If you look at the pump you will see three bolts that go into the housing. This should give you an idea where the forth is.

1. remove air intake pipe, and box (upper and lower section)
2. take off timing belt cover
3. take off serpintine belt, and v belt
4. rotate engine to TDC marks line up on crank and cam. camshaft says O^T on it and on the cover behind gear, crank has a notch in the pulley and a arrow on the cover to line up
5. remove crank pulley 6mm allens not the 19mm 12 bolt
6. make sure timing belt is still at TDC remove lower timing belt cover there is 3 bolts and a nut holding it on the nut is by the water pump and the bolts are on on top and 2 behind the crank pulley
7. remove cover
8. mark intermediate shaft shaft right above the crank pulley
9. remove belt
10. install reverse of removal make sure to line up all 3 pulleys cam crank and intermediate shaft or it wont run and depending on how bad it is out of time if you do it wrong you could bend valves

Assuming this is a 2.0 8v your question is pretty vague

Hi there,

Below are the procedures to remove the timing belt...

1. Disconnect negative battery cable.


2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air conditioning (A/C) compressor drive belt. 3. Remove P/S and/or A/C drive belt.



4. Loosen generator mounting bolts and adjusting bolt. 5. Remove generator bolts.




6. Remove water pump pulley.




7. Remove crankshaft pulley and timing belt guide plate.






8. Remove upper and lower timing belt covers.





9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.







10. Check that "I" mark on intake camshaft pulley is aligned with mark on cylinder head cover and "E" mark on exhaust camshaft pulley is aligned with mark on cylinder head cover.


Do not move camshaft or crankshaft once timing marks have been correctly positioned.







11. Loosen tensioner pulley lock bolt.
12. Protect timing belt with a rag.
13. Remove tensioner pulley.




14. Remove timing belt.



Regards,
Jeep Brainy

Tune-up Specifications
Air/Fuel Ratio 0.7% Air/Fuel Ratio-Limits[1] 0.3 - 1.1% Timing[2] 6°+/- 1°BTDC Timing Advance[3] 30°+/- 3°BTDC Idle RPM[4] 800 +/- 50 [1] Check CO with the oxygen sensor connected. [2] AT 2300 RPM, and coolant temperature sensor disconnected. [3] Normal operating temperature, with coolant temp. sensor connected, at 2300 RPM. Add initial timing. [4] A/C off.
Timing mark is on flywheel, access hole is on top of bellhousing. Remove access plug with 27mm wrench if necessary
Firing Order is > 1342 Clockwise Rotation & #1 Plug Wire is at 2 Oclock on Distribitor Cap


Align the mark (can be a dot or notch) on the intermediate shaft sprocket with the notch in the crank pulley. Align the mark (can be a dot or notch) on the "Back" of camshaft sprocket with the top edge of the valve cover gasket. Be sure all the timing marks are properly aligned.

For further information refer to Timing Belt : Service and Repair
NOTE : The 8 valve engine requires a special wrench, Volkswagen No. US4493 or equivalent, to adjust the camshaft drive belt tensioner. Whenever the drive belt is removed and refitted, the camshaft and intermediate shaft timing MUST be adjusted. The drive belt can be replaced without removing the belt sprockets.

1. Loosen alternator adjusting bolts and remove the fan belt.
2. Remove the water pump pulley bolts and remove the pulley.
3. Remove the upper timing cover bolts and remove the cover.
4. Remove the timing belt guide, if equipped.
5. Turn the engine by hand to set the No. 1 piston at Top Dead Center (TDC) and remove the crankshaft pulley.
6. Remove bolt and nuts securing the lower timing cover and remove the cover. CAUTION: Turning the camshaft or crankshaft with the timing belt removed may cause damage to pistons and/or valves.
7. Loosen timing belt tensioner locknut, release belt tension and remove belt from sprockets.
8. Inspect belt for visible damage such as missing teeth or exposed threads. Inspect tensioner bearing for smooth running. Any damaged components should be replaced.

NOTE : On high mileage engines, failure of the tensioner bearing is a possibility. Consider replacing the bearing when replacing the timing belt.

1. Align the mark (can be a dot or notch) on the intermediate shaft sprocket with the notch in the crank pulley. Align the mark (can be a dot or notch) on the "Back" of camshaft sprocket with the top edge of the valve cover gasket. Be sure all the timing marks are properly aligned.
2. Temporarily install the crankshaft pulley to the crankshaft. Fit the timing belt starting with the crankshaft and intermediate shaft sprockets. Fit the belt so that it is as tight as possible between the crankshaft and the intermediate shaft sprockets and between the intermediate shaft and camshaft sprockets.
   1. Turn the belt tensioner clockwise to adjust the tension. The direction is important to avoid contact with the timing cover. Check the tension by twisting the belt as shown. You should be able to twist it no more than 90 degrees.
   2. Tighten the tensioner locknut to: 33 ft lbs (45 Nm)
   3. Rotate the crankshaft two revolutions and recheck the belt tension and the timing marks for proper alignment.
   NOTE: Very slight movement of sprockets and marks can be expected as belt tension is adjusted. Slight movement is OK. The smallest possible increment of adjustment is one whole tooth of the belt or sprocket.
   1. Remove the crankshaft pulley and refit the lower timing cover. Tighten the bolts to: 87 in lbs (10 Nm)
   2. Refit crankshaft pulley and tighten the bolts to: 15 ft lbs (20 Nm)
   3. Refit timing belt guide, if equipped.
   4. Refit upper timing cover and tighten bolt and nuts to: 87 in lbs (10 Nm)
   5. Refit water pump pulley and tighten the bolts to: 15 ft lbs (20 Nm)
   6. Refit fan belt and adjust tension. Tighten alternator adjusting bolts.
   
   Please Dont Forget To RATE ME !
   

how to change a timing belt