Contents: Removal ↓ Engines AEY, ANV, AKW ↓ Engines AFN, AHU, ALE ↓ For all engines ↓ Installation ↓
Removal
1. Remove the ribbed belt.
2. Remove the ribbed belt tensioner roller, if installed.
3. Remove the upper part of the timing belt cover and the cylinder head cover.
4. Align the TDC marks of the piston of cylinder No.1 on the crankshaft: A - AEY, AHB, AKW engines, B - AFN, AHU, ALE engines (Fig. 6.3).
Engines AEY, ANV, AKW
5. Install adjusting tool 2068 A as shown in Fig. 6.4. Set the adjusting tool to 5 mm (arrow A). Rotate the crankshaft so that the TDC marks on the flywheel coincide with the mark on the setting tool (arrow B).
Engines AFN, AHU, ALE
6. Install the 2068 A adjuster as shown in Fig. 6.5. Set the adjuster to 96.0 mm. The reference point is the graduated mark on the left side of the vernier (arrow A). Rotate the crankshaft until the TDC marks on the flywheel align with the mark on the adjuster (arrow B).
For all engines
7. Lock the camshaft pulley using the lock (Fig. 6.6).
8. Lock the fuel injection pump pulley using the locking pin (Fig. 6.7).
9. Loosen the tension roller.
10. Remove the coolant pump pulley (use VAG 1590 to loosen and tighten the mounting bolt).
11. Remove the crankshaft pulley/damper.
12. Remove the lower part of the timing belt cover.
13. Mark the direction of rotation of the timing belt.
14. Remove the intermediate roller.
15. Remove the timing belt.
Installation
16. Make sure that the TDC mark on the flywheel and the reference point are aligned.
17. Loosen the camshaft pulley mounting bolt by 1/2 turn (Fig. 6.8). Disconnect the pulley from the hub using a hammer and punch.
18. Install the timing belt in the direction of travel and remove the fuel injection pump pulley locking pin.
19. Install the intermediate roller. Tightening torque - 25 Nm.
20. Tighten the timing belt (Fig. 6.9). Using a wrench, turn the tension roller in the direction of the arrow (clockwise) so that the marks (arrows) align.
21. Tighten the tension roller locking nut. Tightening torque: 20 Nm.
22. Check again that the TDC mark on the flywheel and the reference point are aligned.
23. Tighten the camshaft pulley mounting bolt to 45 Nm.
24. Remove the camshaft pulley retainer.
25. Turn the crankshaft two revolutions in the direction of rotation so that the TDC marks on the crankshaft are aligned.
26. Check the alignment of the TDC marks on the flywheel, check the locking of the camshaft pulley using a locking device, check the locking of the fuel injection pump pulley, check the installation and ease of rotation of the tension roller.
27. If the marks are not aligned, pull the tension roller with a wrench, loosen the fastening nut, rotate the eccentric clockwise so that the marks are aligned, and tighten the nut to 45 Nm.
28. Turn the crankshaft two revolutions in the direction of rotation so that the TDC marks on the crankshaft are aligned.
29. Repeat the checks.
30. Install the timing belt cover parts, damper and cylinder head cover.
31. Install the ribbed belt.
32. Check the fuel injection pump supply.
The original information is posted on the resource VWManual
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