Timing belt and timing gears (VW Golf 2)

If the engine is in the vehicle, the following steps must first be performed:

1. Disconnect the battery ground wire.

2. Remove the alternator V-belt.

3. Unscrew and remove the water pump pulley (photo 1.138).



4. Unscrew and remove the upper timing belt cover.

5. Loosen the nuts and bolts of the valve cover and remove the cover together with the gasket and reinforcing belts. Disconnect the crankcase air bleed pipe.

6. Mark the location of the crankshaft pulley relative to the crankshaft gear, then unscrew the four socket head bolts and remove the pulley (photo 1.119).



7. Unscrew and remove the lower distribution cover.

8. Loosen the fastening bolts of the timing gear on the timing shaft, on the intermediate shaft and on the crankshaft. Each of the timing gears is screwed with a bolt and washer. To immobilize the crankshaft while unscrewing the fastening bolt, it is necessary to insert a strip extractor of the starter.



Now it is necessary to check the engine timing installation. Put on the crankshaft pulley for a while. On the intermediate shaft gear, one of the teeth has a hammered point. Rotate the crankshaft until this point coincides with the notch on the crankshaft pulley.

Note: It is easier to turn the crankshaft after removing the spark plugs.

When these markings are aligned, look at the camshaft gear. The dot stamped on one of the teeth of this gear should coincide with the upper edge of the head cover (figure 1.13A). If after crankshaft rotation the markings are in the described positions, look at the cams of cylinder 1 or the cylinder closest to the timing belt. Both cams should be in the closed valve position. Then look through the hole in the clutch housing above the flywheel. The "0" mark on the flywheel should be opposite the mark in the hole in the clutch housing. This means that the piston of the first cylinder is in the TDC position

9. Loosen the tensioner, then remove the timing belt from the timing shaft, intermediate gear and crankshaft gear.

10. Unscrew and remove the fastening bolts and timing gears, then remove the gears, tapping them with a hammer if necessary. Check the fit of the tongues in the grooves and, if there is a gap, replace them. If they are normal, they must be saved together with the corresponding toothed gears.

Installation

1. Insert the tongue into the groove on the intermediate shaft, then fix the toothed gear on the shaft. Place the spacer washer on the bolt, then insert and tighten the bolt to a certain torque. Make the toothed gear stationary while tightening the bolt (photo 1.149).



2. Place (insert) the tongue in the groove of the front part of the crankshaft, put the timing belt gear on the shaft.

Lubricate the mounting bolt, put a spacer washer on it, insert the bolt and tighten it with the appropriate torque. When tightening the bolt, do not allow the crankshaft to turn, using the same method as when unscrewing it.

3. Insert the tongue into the groove at the front of the timing shaft and put on the timing shaft gear. Insert the fastening bolt together with the spacer washer and tighten to the appropriate torque.

4. While tightening the bolt, immobilize the gear by inserting a screwdriver into one of the holes and blocking the engine block or head.

5. If it is removed, put it on the gear wheel (by placing the previously made designations on one line) and tighten one bolt for the time being.

6. Turn the timing gear so that both cams of cylinder No.1 are in the closed valve position, and the mark on the timing gear should coincide with the upper edge of the head cover.

7. Rotate the crankshaft gear and intermediate shaft gear until the mark on the intermediate shaft gear matches the mark on the crankshaft pulley. Put on the timing belt tensioner and put on the timing belt. Check that the marks have not shifted, put a wrench on the tensioner and tighten the belt so that it can be turned no more than 90° with your thumb and forefinger, grasping it in the middle between the camshaft and the intermediate shaft gear. Tighten the eccentric tensioner nut to the appropriate torque.

8. Unscrew and remove the crankshaft pulley.

9. Put the lower timing cover back on, then put the crankshaft pulley back on and tighten the mounting bolts.

10. Put a new valve cover gasket on the engine head, cover seal of the camshaft bearing No.1 (photo 1.140) and a semi-circular sealing ring at the rear of the engine head (photo 1.141).





11. Put on the valve cover, reinforcing belts, then put on and evenly tighten the fastening nuts.

12. Install the upper timing belt cover.