How do you replace broken timing belt on 93 2.5 ltr VW Eurovan?

0. Jack up car. Put on jack stands, remove front passenger wheel. Or put on lift if you have one. Rotate crank until number 1 cylinder TDC (flywheel viewing hole on bell housing has viewing hole. Look to see the mark on the flywheel lines up with the middle mark on the bell housing.

1. Remove serpentine belt (ribbed belt). Need a special tool to depress the tensioner. Have a friend depress the tensioner with the special tool and slip the belt off. Be careful, you can loose a finger here.

2. Remove upper timing belt cover.

3. Use an Allen wrench and loosen the tensioner for the the timing belt. The tensioner pivots off it's center so pull Allen wrench down towards front of car. The have a buddy slip the belt off the cam sprocket. Now it will be loose except for the crank. You cannot get it off without taking the crank pulley off.

4. Remove crankshaft pulley (harmonic balancer). You need a special tool to hold the pulley while you crack the bolt. Take off the pulley. Also take off the plastic lower timing belt cover (this is a PITA). You may try to get it off before. I broke mine in half doing this.

Once off you are clear. I recommend getting a timing belt change kit. I just bought one on EBAY for a 93 Eurovan. Replace water pump, timing belt idler pulley and tensioner.

Now make sure your timing marks are lined up. For the cam it's a groove on the sproket side that faces the engine. Line the groove up with the tooth on the inner timing belt housing (back sheetmental that is on the inside of the sprocket. Also line up the number 1 TDC mark on the flywheel thru the view hole on the trans bell housing.

Now just reverse the steps!