Attention! Cylinder number 1 is located, when viewed in the direction of travel, on the right side of the engine.
1. Remove the protective cover from the motor.
2. Remove the top cover of the gas distribution mechanism by unscrewing the mounting bolts.
3. Turn the crankshaft in the direction of engine rotation (clockwise), so that the notch on the belt pulley coincides with the edge of the reference mark -0- (see illustration). To turn the crankshaft, engage neutral gear and turn the crankshaft by the center bolt with a curved socket wrench or a 19 mm socket.
Attention! It is not allowed to turn the engine by the toothed belt gear bolt on the camshaft. In this case, the toothed belt is overtensioned.
The alignment holes on the gears must match the dowel pin holes on the camshaft flanges (see arrows in illustration 4.0).
Attention! If the holes for the dowel pins on the camshaft flanges are on opposite sides of the gears, then the crankshaft must be rotated again.
Attention! This manual does not provide a detailed procedure for removing and installing the timing belt for vehicles with a 1.4 liter 55 kW gasoline engine (75 hp) VSA. Only the main points regarding the installation of the belt are given.
Fixing the camshaft gears at TDC of the piston of cylinder No. 1
4. Set the piston of cylinder No. 1 to TDC.
5. Insert the pins of the retainer, for example, HAZET-2588-4 or VW-T-10016, into the holes for the landing pins on the gears of the camshaft drive until they stop. The locking device is considered to be installed correctly if the tips D of its fingers are in line with the axis A (see illustration).
6. Insert holder B until it touches gear C of the intake camshaft (see illustration 4.5).
Installation of the tension roller for the timing belt of the exhaust camshaft drive
7. Turn the tension roller of the toothed belt of the exhaust camshaft drive by the hexagon 1 clockwise in the direction of the window with the reference mark (see arrow in illustration). In this case, the tension of the toothed belt is loosened.
8. Install the tension roller in place and wring it out together with the laid toothed belt up. In this position of a roller screw in a bolt of fastening of a roller.
9. Tighten the roller fixing bolt by hand. The protrusion on the base plate must fit into the hole on the cylinder head 2 (see illustration 4.7).
10. Tension the toothed belt by turning the tension roller on the hexagon 1 counterclockwise until arrow 2 is positioned on the tab on the base plate (see arrow in illustration). In this position of the roller, tighten the bolt of its fastening 3 with a force of 20 Nm.
Tension of the timing belt of the gas distribution mechanism
11. Turn the toothed belt tensioner by the hexagon (see arrow in illustration) counterclockwise until the roller is positioned as shown in the illustration. This operation is performed in cases where the roller has been dismantled before.
12. Tighten the bolt 2 fastening the roller by hand (see illustration). Lug 1 on the base plate must fit over bolt 2.
13. Turn the tension roller with a hex socket wrench in the direction of the left arrow, as shown in illustration 4.12, so that arrow 3 is located above the notch on the base plate (see right arrow in illustration 4.12).
Tighten the roller fixing bolt to 20 Nm.
15. Remove the fixing device from the gears of the camshafts.
16. Turn the crankshaft two turns and check the position of the toothed belt tension roller.
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