Remove the upper and lower front toothed belt covers. Turn the engine crankshaft until the mark on the flywheel aligns with the installation lug in the clutch housing hatch, which corresponds to TDC of the compression stroke of piston No.1 (Fig. 3-18). Remove the cylinder head cover. Lock the camshaft with the VW 20 65 locking tool (Fig. 3-19). as specified in the subsection "Removing and installing the high-pressure fuel pump". Make sure that the mark on the high-pressure fuel pump drive toothed pulley is aligned with the mark on the high-pressure fuel pump housing (Fig. 3-20). If the marks are not aligned, remove the locking tool from the camshaft and turn the crankshaft one revolution, then lock the camshaft with the locking tool again. Lock the fuel injection pump drive pulley with the VW 20 64 lock. Loosen the tension roller nut and loosen the toothed belt tension by turning the roller. Remove the toothed belt.
For installing belts 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 striking a punch inserted through the hole in the rear toothed belt cover. Make sure that the TDC mark on the flywheel is precisely aligned with the installation protrusion in the clutch housing hatch. Put the toothed belt on the pulleys, ensuring that the teeth are aligned correctly. Slightly tighten the belt to hold it in place. Remove the VW 20 64 locking device for the high-pressure fuel pump toothed pulley. Install the VW 210 device (Fig. 3-21) for checking the toothed belt tension on the belt branch between the camshaft and high-pressure fuel pump toothed pulleys. Loosen the tension roller nut. By turning the tension roller, adjust the tension of the toothed belt so that the arrow on the device is between the 12th and 13th divisions on the scale.
Fig. 3-21. Checking and adjusting the toothed belt tension using the VW 210 tool:
1 - VW 210 fixture;
2 — tension roller lock key V-159;
3 — lock nut;
4 — camshaft toothed pulley mounting bolt.
On the 1Z and AFN engines, the 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 toothed pulley mounting bolt to a torque of 4.5 kgf·m. Manually turn the crankshaft two turns and again check the correct installation and adjustment of the toothed belt tension. Install the cylinder head cover. Install the upper and lower front toothed belt covers. Place the alternator drive belt and, depending on the vehicle model, the power steering pump drive belt on the pulleys and adjust their tension as indicated below. Check the fuel injection advance angle setting as indicated below. Connect the wire to the negative terminal of the storage battery.
(The original article is available on the website: www.VWmanual.ru)
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