Fig. 415. The upper figure shows the adjusting gauge 1 installed on the camshaft. The lower figure shows how the flywheel with the TDC mark should be positioned
When installing a new drive belt or reinstalling an old belt, first make sure that the flywheel is in the position shown in Fig. 415.
Loosen the camshaft timing gear bolt by 1/2 turn (without turning the shaft) and hit it with a plastic or rubber mallet to loosen the bevel fit of the gear on the shaft. If using an old drive belt, install it according to the mark regarding the direction of travel.
Tighten the timing belt guide roller (25 Nm) and remove the thrust pin from the injection pump toothed wheel.
Fig. 419. Installing the toothed belt. Pay attention to the alignment of the marks on the tension roller (inset with arrow in the picture). Instead of a special tool, you can use beveled snap ring cutters: 1 - running roller; 2 - a special tool or pliers for removing spring retaining rings; 3 - tension roller; 4 - locking pin
Inspect the tensioner pulley. It has a rib and a groove that should fit together. Fig. 419 shows what the belt looks like at this stage of installation.
Now press the tension roller with the snap ring pliers against the spring tension (direction 3 in Fig. 419) and tighten the tension roller nut to 20 Nm.
Fix the camshaft gear in a stationary position and tighten the bolt to a torque of 45 N·m.
Remove the adjusting gauge from the other side of the engine.
Reinstall all parts. Raise or lower the vehicle to the ground to be able to access individual parts.
Rotate the crankshaft pulley and turn the engine two full revolutions. Then check whether the TDC position still corresponds.
After adjusting the drive belt, check the injection adjustment.
Install the lower timing belt guard (3 bolts).
Screw the crankshaft pulley with the vibration damper onto the timing gear and tighten the four bolts to 25 Nm. The dowel pin on the crankshaft gear must fit into the hole on the vibration damper. When tightening the connection, lock the crankshaft in a stationary position (you can turn on the transmission).
Install the upper toothed belt guard. It should fit into the groove of the lower guard.
(The original can be viewed on the portal VWmanual)
Install the drive belt and the power steering pump V-belt and adjust their tension.
Fig. 393. Unscrew bolts 1 and 2
Reinstall the front engine mount clamp (large bolts tightened to 58 N·m, small bolts tightened to 23 N·m) and the engine mount. Fig. 393 shows the engine mount fastening from the front.
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