Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Pin wrench Matra V159.
• ◆ Torque wrench V.A.G 1331 (5...50 Nm).

Removing

• ‒ Loosen tensioning bracket and remove alternator V-belt
  .
• ‒ Remove vibration damper/belt pulley, coolant pump pulley and toothed belt guard upper and lower parts.
• ‒ Mark direction of travel of toothed belt.
• ‒ Loosen tensioner and take off toothed belt.

Installing

• ‒ → The mark on the camshaft sprocket must be in line with the cylinder head cover.
• ‒ Place toothed belt on crankshaft sprocket and intermediate shaft sprocket (note direction of rotation).
• ‒ Secure the vibration damper/belt pulley on the crankshaft with one bolt (note installation position, holes off-set).
• ‒ Align the marks on the vibration damper/pulley and intermediate shaft sprocket (TDC No. 1 cylinder).

• ‒ → Ensure that distributor rotor arm is pointing to No. 1 cylinder on the distributor housing. Should this not be the case, rotate the distributor body until alignment is achieved. If necessary remove and install distributor in correct position.
• ‒ Install toothed belt on camshaft sprocket.

• ‒ → Tension toothed belt, to do this turn tensioner with pin wrench Matra V159 in direction of arrow.
• ‒ It must be possible to turn the toothed belt through 90° with the thumb and forefinger in the center between camshaft and intermediate shaft sprockets.
• ‒ Tighten retaining nut on tensioner.
  Tightening torque: 45 Nm.
• ‒ Rotate crankshaft two full turns and recheck adjustment.
• ‒ Remove vibration damper/belt pulley from crankshaft.
• ‒ Install toothed belt guard lower part.
• ‒ Install vibration damper/belt pulley, coolant pump pulley and toothed belt guard upper part.
• ‒ Install alternator V-belt => Page 13-12.
• ‒ Check and if necessary adjust ignition timing:

=> Repair group 28