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)

Note:

The Motronic control unit requires the No. 1 cylinder TDC signal from the Hall sender to allocate the injection and knock sensor systems as per firing order.

Checking No. 1 cylinder TDC markings:

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

Engine removed

• ‒ → Set vibration damper (V-belt pulley) to TDC No. 1 cylinder.

• ● → Mark on camshaft sprocket must align with arrow on cylinder head cover.

• ● → Mark on distributor must align with mark on rotor arm or Hall sender cover.

Removing and installing distributor

Test conditions

• ● Crankshaft and camshaft in No. 1 cylinder TDC position

Work sequence

• ‒ Remove distributor.

• ‒ → Before installing the distributor align oil pump shaft drive tongue parallel to crankshaft.

• ‒ → Install distributor. The pins on the distributor must point towards securing bolt threaded hole -arrow-.

Note:

When installing, turn rotor arm slightly right of the distributor marking. When inserting the rotor arm will turn back onto the marking.

• ● → Mark on distributor must align with mark on rotor arm or Hall sender cover.

• ‒ Tighten distributor securing bolt.
       Tightening torque: 25 Nm

If no alignment of the markings can be achieved:

• ‒ Loosen tensioning roller and take toothed belt off camshaft sprocket.

• ‒ → 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).

• ● → Mark on distributor must align with mark on rotor arm or Hall sender cover.

• ‒ 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.

• ‒ → 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.
• ‒ Before fitting, clean distributor cap and check for cracks and signs of tracking, renew if necessary.