Contents: Engines "KR" and "9A" ↓ Engine "ABF" ↓
Engines "KR" and "9A"
To remove, disconnect the wires from the battery terminals. Remove the 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 drive belt protective covers.
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 mark on the clutch housing and make sure that the mark on the exhaust camshaft pulley is at the level of the cylinder head plane. Loosen the tension roller fastening nut.
Remove the camshaft timing belt.
To install, turn the exhaust camshaft to the TDC position of the compression stroke of piston No.1 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 piston is at TDC.
Align the mark on the crankshaft pulley with the mark on the intermediate shaft toothed pulley.
Place the timing belt on the pulleys. Adjust the timing belt tension by turning the tension roller clockwise using the V 159 key (fig. 2-147). Check the timing belt tension using the VW 210 tool (13 or 14 fixed positions). If you do not have a device, check the belt tension by turning it with your thumb and index finger around its axis in the middle of the branch between the camshaft pulley and the intermediate shaft pulley. When the tension is adjusted correctly, the belt should not turn more than 90°. Turn the crankshaft two revolutions and check the toothed belt tension again. Install the front protective covers of the camshaft drive belt. Put the alternator drive belt on the pulleys, adjust its tension as specified in the section "Electrical equipment" and tighten the generator mounting bolts. Connect the air duct to the air flow meter and the throttle body. Connect the wires to the battery terminals.
Engine "ABF"
To remove, disconnect the wires from the battery terminals. Remove the 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 with the VAG 3299 lever, then remove the tension roller. Remove the crankshaft pulley. Remove the upper and lower protective covers of the camshaft drive belt. Unscrew the spark plugs to make it easier to turn the crankshaft. Turn the crankshaft to the TDC position of the compression stroke of piston No.1, aligning the mark on the flywheel with the mark on the clutch housing (fig. 2-149) or the mark on the crankshaft pulley with the mark on the rear timing belt cover.
(The original text can be found on the portal: VWMANUAL)
Fig. 2-149. Timing marks for installing the camshaft drive toothed belt:
1 - mark on the toothed pulley of the exhaust camshaft;
2 - mark on the crankshaft pulley;
3 - tension roller.
The arrows show the marks on the camshaft sprockets
Set the exhaust camshaft to the TDC position of the compression stroke of piston No.1 cylinder, 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 (fig. 2-149). With the cylinder head cover removed, turn the exhaust camshaft to a position where the mark on the rear end of its toothed pulley is level with the cylinder head plane on the intake camshaft side. Loosen the tension roller mounting nut. Remove the toothed belt, having first marked it with the direction of rotation in case of its further use.
To install, check the alignment of the timing marks to ensure that the exhaust camshaft is in the correct position and make sure that the crankshaft is in the TDC position of the compression stroke of the piston of the 1st cylinder.
Warning: Do not turn the exhaust camshaft when any piston is at TDC.
Put the toothed belt on the pulleys. When installing a reusable belt, pay attention to the previously applied marks of the belt rotation direction. Adjust the tension of the toothed belt by turning the tension roller counterclockwise until it stops, then release it until the marks align (fig. 2-150) and tighten the roller mounting nut to a torque of 4.5 kgf·m. Turn the crankshaft two revolutions and check the alignment of the timing marks. Press hard on the longest branch of the toothed belt so that the timing marks shift relative to each other. When releasing the belt, the marks should align again. Install the upper and lower front toothed belt protective covers.
Install the crankshaft pulley, tightening its mounting bolt to a torque of 2 kgf·m. Install the alternator drive belt. Install the power steering pump drive belt and its tension roller. Tighten the spark plugs. Install the air duct 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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