Remove the upper and lower front toothed belt guards. Turn the crankshaft of the engine until the mark on the flywheel aligns with the mounting protrusion in the hatch of the clutch housing, which corresponds to the TDC of the compression stroke of the piston of the 1st cylinder (pic. 3-18). Remove cylinder head cover Lock camshaft with lock VW 20 65 (pic. 3-19). as stated in subsection «Removal and installation of injection pump». Make sure that the mark on the gear pulley of the injection pump drive is aligned with the mark on the injection pump housing (pic. 3-20). If the marks are not aligned, remove the lock from the camshaft and rotate the crankshaft one turn, then again block the camshaft with the lock. Block the injection pump drive pulley with the VW 20 64 lock. Remove toothed belt.
For installing a belt on engines «AAZ», «1Z» and «AFN» loosen the camshaft toothed pulley fastening nut by half a turn and separate the pulley from the cone by hitting the drift inserted through the hole in the rear toothed belt protective cover. Make sure that the TDC mark on the flywheel is exactly aligned with the alignment lug in the clutch housing hatch. Slide the toothed belt over the pulleys, making sure the teeth are in the correct alignment. Slightly tighten the belt to hold it in place. Remove retainer VW 20 64 for injection pump sprocket. Install tool VW 210 (pic. 3-21) to check the tension of the toothed belt on the belt branch between the toothed pulleys of the camshaft and the injection pump. Loosen the tension roller nut. By turning the tension roller, adjust the tension of the toothed belt so that the arrow of the tool is between the 12th and 13th divisions of the scale.
Pic. 3-21. Checking and adjusting the toothed belt tension using the VW 210 tool:
1 - fixture VW 210;
2 - key for blocking the tension roller V-159;
3 - locknut;
4 — a bolt of fastening of a gear pulley of a camshaft.
On the engine «1Z» and «AFN» belt tension is adjusted by turning the tension roller until the marks on the eccentric and tension roller are aligned. Tighten the tension roller nut. Remove the camshaft retainer. Tighten the camshaft sprocket bolt to 4.5 kgf·m. Rotate the crankshaft two turns by hand and again check that the toothed belt is correctly positioned and adjusted. Install the cylinder head cover. Install the upper and lower front toothed belt guards. Fit the alternator drive belts and, depending on the vehicle model, the power steering pump belts onto the pulleys and adjust their tension as indicated below. Check the fuel injection advance setting as indicated below. Connect the wire to the negative terminal of the battery.
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