Volkswagen Workshop Service and Repair Manuals

(Adjusting valve timing)

See notes .

Special tools, testers and auxiliary items

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

Removing

• ‒ Remove ribbed belt => Page 13-13 .
• ‒ Remove ribbed belt tensioning roller.
• ‒ Remove vibration damper/belt pulley, coolant pump pulley and toothed belt guard upper and lower parts.
• ‒ Mark D.O.R. of toothed belt.
• ‒ Release tensioner and take off toothed belt.

Installing

Note:

• ◆ For repairs which require the toothed belt to be removed, carry out the toothed belt adjustment as follows.
• ◆ When turning the camshaft the crankshaft must not be at TDC. Danger of damage valves/piston crown.

• ‒ → Bring mark on camshaft sprocket in line with the mark on toothed belt guard.
• ‒ Place toothed belt on crankshaft sprocket and intermediate shaft sprocket (note direction of rotation).

Note:

The mark on the intermediate shaft sprocket is of no consequence.

• ‒ Install toothed belt guard lower part.
• ‒ Install crankshaft vibration damper and pulley (note installation position, holes off-set).
• ‒ Set crankshaft to TDC.

→ Engine installed:

• ‒ Set flywheel -A- or drive plate -B- to TDC No. 1 cylinder.

→ Engine removed:

• ‒ Set vibration damper to TDC No. 1 cylinder.

• ‒ → Turn intermediate shaft sprocket with toothed belt so long in direction of arrow until rotor arm aligns with markings for No. 1 cylinder on distributor housing (toothed belt slides over crankshaft sprocket).
• ‒ Place toothed belt on tensioning roller and camshaft sprocket.

Note:

For easier installation of the toothed belt loosen tensioner roller lock nut only approx. one thread.

→ No. 1 cylinder marking on distributor body.

• ‒ → Tension toothed belt, to do this turn tensioner with pin wrench (e.g. Matra V159) in direction of arrow.

It must just be possible to turn the toothed belt through 90° with the thumb and forefinger in the centre between camshaft and intermediate shaft sprockets.

• ‒ Tighten tensioner lock nut.
       Tightening torque: 45 Nm
• ‒ Rotate crankshaft two full turns and check adjustment.
• ‒ Check distributor housing and rotor arm markings.
• ‒ Install upper toothed belt protective cover.
• ‒ Install ribbed belt tensioner.
       Tightening torque: 20 Nm
• ‒ Install ribbed belt => Page 13-13 .