Engines «KR» AND «9A»
To remove, disconnect the wires from the battery terminals. Remove air duct. connecting the air flow meter to the throttle body. Loosen the alternator mounting bolts and remove the alternator drive belt. Remove the front camshaft belt guards.
Turn the crankshaft to the TDC position on the compression stroke of the 1st cylinder, aligning the mark on the flywheel with the alignment mark on the clutch housing and make sure that the mark on the exhaust camshaft pulley is at the level of the plane of the cylinder head. Loosen the nut securing the tension roller.
Remove the camshaft timing belt.
To install, turn the exhaust camshaft to the TDC position of the compression stroke of the 1st cylinder, turning the exhaust camshaft so that the mark on its pulley is at the level of the plane of the cylinder head from the front of the car.
Warning. Do not turn the exhaust camshaft. when any of the pistons is at TDC.
Align the mark on the crankshaft pulley with the mark on the countershaft sprocket.
Fit the camshaft timing belt onto the pulleys. Adjust the tension of the toothed belt by turning the tension roller clockwise using the key V 159 (pic. 2-147). Check toothed belt tension with tool VW 210 (for 13 or 14 fixed positions). In the absence of a tool, check the belt tension by turning it with the force of the thumb and forefinger around its axis in the middle of the branch between the camshaft pulley and the intermediate shaft pulley. When properly adjusted, the belt should not rotate more than 90°. Rotate the crankshaft two turns and recheck the toothed belt tension. Install the front camshaft belt guards. Put the alternator drive belt on the pulleys, adjust its tension, as indicated in the section «electrical equipment» and tighten the alternator mounting bolts. Connect the air line to the air flow meter and throttle body. Connect the wires to the battery terminals.
Engine «ABF»
To remove, disconnect the wires from the battery terminals. Remove air duct. connecting the air filter to the throttle body. Remove the power steering pump drive belt. Remove the alternator drive belt by lifting its tension roller using the VAG 3299 lever, and then remove the tension roller. Remove the crankshaft pulley. Remove the upper and lower camshaft belt guards. Unscrew the spark plugs to make it easier to turn the crankshaft. Turn the crankshaft to the TDC position on the compression stroke of the 1st cylinder, aligning the mark on the flywheel with the mark on the clutch housing (pic. 2-149) or the mark on the crankshaft pulley with the mark on the rear toothed belt guard.
Pic. 2-149. Timing marks for installing a toothed camshaft drive belt:
1 — a label on a gear pulley of a final camshaft;
2 - mark on the crankshaft pulley;
3 - tension roller.
The arrows show the marks on the camshaft sprockets
Set the exhaust camshaft to TDC on the compression stroke of the 1st cylinder by turning the exhaust shaft so that the mark on the front end of its toothed pulley aligns with the mark on the cylinder head cover, if installed (pic. 2-149). With the cylinder head cover removed, turn the exhaust camshaft so that the mark on the rear end of its toothed pulley is at the same level as the plane of the cylinder head on the intake camshaft side. Loosen the nut securing the tension roller. Remove the toothed belt, having previously marked the direction of rotation on it in case of its further use.
To install, check the alignment of the alignment marks for the correct position of the exhaust camshaft and make sure that the crankshaft is in the TDC position of the compression stroke of the 1st cylinder.
Warning. Do not turn the exhaust camshaft when any of the pistons is at TDC.
Put the toothed belt on the pulleys. When installing a reusable belt, pay attention to the previously marked marks for the direction of rotation of the belt. Adjust the tension of the toothed belt, for which turn the tension roller counterclockwise to failure, then release it until the marks are aligned (pic. 2-150) and tighten the roller fastening nut to a torque of 4.5 kgf·m. Rotate the crankshaft two turns and check that the alignment marks are aligned. With force, press the branch of the greatest length of the toothed belt so. so that the alignment marks are offset relative to each other. When the belt is released, the marks should line up again. Install the upper and lower front toothed belt guards.
Install the crankshaft pulley by tightening its fastening bolt to a torque of 2 kgf·m. Install the alternator drive belt. Install the power steering pump drive belt and idler pulley. Screw in the spark plugs. Install the air line connecting the air filter to the throttle body. Connect the wires to the battery terminals. Check and, if necessary, set the ignition timing.
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