Removal
Loosen the generator mounting bolts and, depending on the configuration, the power steering pump mounting bolts.
Remove the alternator drive belt and, depending on the configuration, the power steering pump drive belt.
Remove the crankshaft pulley.
Remove the front timing belt covers.
Disconnect the high voltage wire harness and remove the spark plugs.
Turn the crankshaft to the TDC position of the compression stroke of the piston of the 1st cylinder, aligning the mark on the flywheel with the installation protrusion on the clutch housing and placing the mark on the toothed pulley of the camshaft at the level of the cylinder head gasket.
Slightly loosen the water pump mounting bolts, turn the pump body counterclockwise to loosen the timing belt tension.
Remove the camshaft drive belt
Installation
Note: Do not allow the camshaft to turn when one of the pistons is at TDC.
Set or check the correct position of the camshaft pulley corresponding to the TDC of the compression stroke of the piston of the 1st cylinder: the mark on the pulley should be opposite the upper plane of the camshaft cover gasket.
Make sure that the crankshaft is in the position corresponding to the TDC of the compression stroke of the piston of the 1st cylinder; in this case, the marks on the flywheel and on the clutch housing must match. When adjusting the valve timing mechanism on a removed engine, align the marks on the crankshaft pulley and the upper edge of the oil pump housing.
Place the camshaft drive belt on the pulleys.
Tighten the belt on the pulley teeth.
Tighten the timing belt by moving the water pump housing.
Turn the crankshaft two revolutions and check the position of the timing marks.
Install the front timing belt covers.
Install the alternator drive belt and, depending on the configuration, the power steering pump drive belt and adjust its tension.
Install the spark plugs and high-voltage wire harness.
Check and, if necessary, adjust the ignition timing.
Checking and adjusting the tension of the camshaft drive belt
Turn the crankshaft clockwise to the position corresponding to the TDC of the compression stroke of piston No.1 cylinder.
Remove the upper front camshaft drive belt cover.
Check the tension of the toothed belt by turning it with the force of your thumb and index finger 90 degrees around its axis in the middle of the branch between the camshaft pulley and the water pump. The belt should not turn more than 90 degrees.
To adjust, loosen the water pump mounting bolts, move the pump body using the adjusting lever up for more tension or down for less belt tension.
Tighten the pump mounting bolts.
Turn the crankshaft two revolutions and check the timing belt tension again.
Install the front camshaft timing belt covers.
Timing mechanism parts:
1 — crankshaft;
2 - toothed pulley of the crankshaft;
3 - toothed belt of camshaft drive;
4 - coolant pump;
5 - toothed pulley of the camshaft;
6 — camshaft;
7 — ignition distributor sensor drive gear;
8 - Front and rear timing belt protective covers;
9 — pusher and valve clearance adjusting washer;
10 - hydraulic pusher;
11 - crackers;
12 — spring support plates;
13 — valve springs;
14 — valves;
15 — oil deflector cap;
16 - guide roller (since 1984 model year).
The original text is available on the portal VWManual
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