Volkswagen Workshop Service and Repair Manuals

(Adjusting valve timing)

Special tools, testers and auxiliary items

• ◆ Lever 3299
• ◆ Pin wrench Matra V159
• ◆ Torque wrench V.A.G 1331 (5...50 Nm)

Engines without semi-automatic tensioning roller:

• ◆ V- and toothed belt test unit VW 210

Removing

• ‒ Remove ribbed belt .
• ‒ Remove ribbed belt tensioning roller.
• ‒ Remove vibration damper and toothed belt guard upper and lower parts.
• ‒ Mark D.O.R. of toothed belt.
• ‒ Release tensioner and take off toothed belt.

Installing

Prerequisites

• ● The engine must be no more than warm to touch.
• ● The pistons must not be positioned at TDC.

Note:

If a piston is at TDC the valves could strike the piston when turning the camshaft.

Work sequence

• ‒ Place toothed belt on crankshaft sprocket and intermediate shaft sprocket (note D.O.R.) and install lower part of toothed belt guard.
• ‒ Install crankshaft vibration damper (note installation position, holes off-set).

• ‒ → Set crankshaft sprocket to TDC No. 1 cyl. marks. Mark on camshaft sprocket must align with the arrow on the cylinder head cover -A-.

With cylinder head cover removed:

Mark on the camshaft sprocket must align with the cylinder head -B-.

• ‒ → Set crankshaft to TDC No. 1 cyl. TDC mark on flywheel and mark on clutch housing must align -D-.

Engine removed:

Mark on vibration damper and mark on toothed belt guard must align -C-.

• ‒ Fit toothed belt onto camshaft sprocket.

Engines without semi-automatic tensioning roller:

• ‒ → Tension toothed belt, to do this turn tensioner with pin wrench (e.g. Matra V159) in direction of arrow.
       Scale reading for VW 210: 13...14
• ‒ Tighten lock nut on the tensioner.
       Tightening torque: 45 Nm

Engines with semi-automatic tensioning roller:

• ‒ → Tension toothed belt, to do this turn tensioning roller in direction of arrow onto stop with pin wrench (e.g. Matra V159).
• ‒ Release tensioner again, until the marks align exactly -arrow-.
• ‒ Tighten tensioning roller clamping nut.
       Tightening torque: 25 Nm

• ‒ Turn crankshaft two complete turns in engine direction of rotation, set again to to TDC and check adjustment.
• ‒ Install toothed belt guard upper part.
• ‒ Install ribbed belt tensioner.
       Tightening torque: 20 Nm
• ‒ Install ribbed belt => Page 13-11 .