The adjustment cam on the tensioner pulley can fracture during the tensioning process. Continental has provided these instructions for timing belt kits CT1168K1/ K2/ WP1/ WP2/ WP7/ WP9/ K6PRO/ WP8PRO that are for VW, Audi, Seat, Skoda EA288 1.4–2.0 TDi common rail engines.

The cause of this fracture is that the fastening nut is over tightened during assembly. As a result, the nut turns together with the eccentric cam during tensioning, subjecting it to an even greater load. This produces too much resistance, causing the adjustment cam to crack (Fig. A).

The solution is to only tighten the nut by hand prior to tensioning. Use an appropriate tool to hold the nut securely (Fig. B & C) so that it doesn’t turn together with the cam. You now tighten the tensioner pulley by turning it clockwise until the pointer aligns with the marker notch (Fig. C). You can then finish tightening the nut.

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