Withdrawal
Remove the top timing belt cover and cylinder head cover.
Set the crankshaft to top dead center on cylinder 1. To do this, turn the crankshaft with the key head on the belt pulley (gearbox is in neutral) before installing the crankshaft of the first cylinder -arrow-. Never turn the crankshaft by the toothed belt pulley.
The crankshaft is at the top dead center position of the first cylinder if the pair of cams of the first cylinder is facing up.
In this position, you can insert the adjusting ruler 206A into the slot of the camshaft.
Block the camshaft with the adjuster. Adjusting ruler (VW No. 206A) has a protrusion that prevents the camshaft from turning.
Check the position with a ruler. To do this, rotate the blocked camshaft until the end of the adjusting bar abuts against the cylinder head. Using a feeler gauge, measure the resulting gap at the other end of the adjusting ruler. Insert a feeler gauge half the measuring gap between the adjusting ruler and the cylinder head. After that, turn the camshaft so that the adjusting ruler rests on the probe. Insert a feeler gauge of the same size from the other end of the adjusting bar between the ruler and the cylinder head.
Block the high pressure fuel pump gear with a suitable pin.
Loosen the tension roller nut and relieve the toothed belt tension.
Attention: When turning the camshaft with the toothed belt removed, none of the pistons must be in the top position. Otherwise severe damage to pistons or valves may occur.
If you need to rotate the camshaft, first set all pistons below dead points. To do this, mark with chalk a line on the top of the crankshaft belt pulley (condition: the crankshaft is at the top dead center position of the first cylinder), then turn the crankshaft pulley ¼ turn (90°) left or right. After that, the chalk mark should be facing right or left.
Loosen and remove the V-belt.
Remove toothed belt.
Installation
Check through the hole in the gearbox whether the TDC marks on the flywheel and the reference mark match.
Loosen the camshaft sprocket bolt ⅓ turn. Knock off the toothed pulley from the camshaft cone with a hammer blow on the rod inserted into the 6 mm hole in the back cover of the toothed belt.
Apply toothed belt according to drawing 13-786 and remove high pressure fuel pump gear fixing pin.
Pull on toothed belt.
Tighten the tensioning roller nut to 45 Nm.
Tighten the camshaft sprocket bolt to 45 Nm.
Remove adjuster bar.
Rotate the crankshaft 2 turns in the direction of engine rotation. Apply a blow with a rubber mallet between the camshaft sprocket and the injection pump gear and check again that the toothed belt tension is correct, if necessary, tighten the belt.
Check the timing of the start of fuel injection of the high pressure fuel pump.
Install V-belt pulley and bottom cover, tension V-belt.
Replace cylinder head cover gaskets, screw on cylinder head cover.
Install the upper toothed belt cover.
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