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POWER PULLEY KIT
1992 – 2002 VOLKSWAGEN 2.8L 12Valve - VR6
PART # 62.10.71
INSTALLATION INSTRUCTIONS
PART LIST: 1 – CRANKSHAFT PULLEY 1 – ALTERNATOR PULLEY
1 – PWR. STRG. PUMP PULLEY 1 – CRANKSHAFT BOLT
TOOLS REQ: 1 – Ratchet 1 – 6mm Hex Socket
1 – 27 mm Socket 1 – Standard Screw Driver
1 – 24 mm Socket 1 – Die grinder and rotary file.
1 – 17 mm Socket 1 – Hammer
1 – 24 mm Wrench (open end) 1 – Chisel
1 – Large Channel-Lock Pliers 1 – T10069 Counter Holder
1. Car hoist required, vehicle not high enough from
ground with a jack or jack stands. Loosen lug nuts
(17mm hex) on right front wheel. Remove right front
wheel.
2. Remove under-panel and lower right engine cover.
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3. Using a 6mm hex socket, loosen bolts securing
power steering pump pulley but do not remove
4. Using a large standard screwdriver, remove
passenger side engine cover.
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5. Remove drive belt by installing a M8 X 1.25 x
80mm bolt in threaded bore on belt tensioner
assembly. Rotate bolt clockwise until belt is loose
enough for removal. Mark running direction on belt
and remove belt.
8. Using VW tool Counter Holder (T10069) and 27
mm socket undo and remove bolt securing crankshaft
pulley.
6. Hold outer edge of alternator pulley with large
channel lock pliers or equivalent. Using a 24mm
socket, loosen alternator nut and remove pulley.
7. Remove bolts securing power steering pump
pulley and remove pulley.
9. Remove crankshaft bolt and crankshaft pulley.
10. Using a grinder or file remove ¼” of material
from corner of crank seal housing. Test fit supplied
crankshaft pulley and check to see that there is at
least 1/8” of clearance between housing and pulley.
Continue to remove material until clearance is
achieved.
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11. With a hammer and chisel, gently remove key
from crankshaft pulley.
14. Position pulley on crankshaft and align key to
keyway. Gently press pulley onto shaft. If pulley
does not slide on shaft easily, remove and check for
burs or corrosion. If any burs or corrosion exists,
remove as necessary. Use of excessive force to
install the pulley will damage both the pulley and
the crankshaft and will void warranty. Install
supplied bolt and torque to 100Nm (74ft-lb.) plus an
additional ¼ turn using VW tool Counter Holder
(T10069) and 27 mm socket.
12. Remove any burs from key.
13. Install key in keyway of supplied crankshaft
pulley and gently tap into position.
15. Install power steering pump pulley and torque
bolts to 20Nm (15ft-lb.)
16. Install supplied alternator pulley on alternator
shaft followed by the washer and nut. Using a 24mm
wrench on alternator pulley, torque nut (24mm) to
65Nm (48 ft.-lb.)
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17. Re-install belt in correct running direction and
slowly remove M8 bolt from tensioner, making sure
belt is correctly seated in pulley grooves.
18. Re-install engine cover and under-panel. Install
wheel and lug nuts. Torque lug nuts to 110Nm (81
ft.-lb.) for original wheels or to wheel manufacture
specifications.
19. Carefully check complete installation to be sure
all fasteners are tight, the belt is correctly seated in
groves of each pulley and that nothing interferes with
the pulleys or belt.
©Copyright 2002, NEUSPEED®. All rights reserved. Reproduction in whole or in part prohibited.
DOC.62.10.71 Rev. 05.30.03
NEUSPEED • 3300 Corte Malpaso • Camarillo, CA 93012 • 805.388.7171 • 805.388.0030 FAX
Visit us on the web…http://www.neuspeed.com
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