Table of contents: Removal ↓ Installation ↓
Removal
Remove the upper timing belt cover and cylinder head cover.
Set the crankshaft to the top dead center position of the first cylinder. To do this, turn the crankshaft with the key head on the belt pulley (gearbox set to neutral) before installing the crankshaft of the first cylinder -arrow-. Never turn the crankshaft by the toothed belt pulley.
The crankshaft is in the top dead center position of the first cylinder if the pair of cams of the first cylinder is facing upward.
In this position, the 206A adjustment ruler can be inserted into the slot of the camshaft.
Lock the camshaft with a straight edge. Straight edge (VW-Nr. 206A) has a protrusion that prevents the camshaft from turning.
Check the position with an adjusting ruler. To do this, turn the locked camshaft until the end of the adjusting ruler rests against the cylinder head. Using a feeler gauge, measure the resulting gap at the other end of the adjusting ruler. Insert a feeler gauge of half the thickness of the measuring gap between the adjusting ruler and the cylinder head. Then turn the camshaft so that the adjusting ruler rests against the feeler gauge. Insert a feeler gauge of the same size from the other end of the adjusting ruler between the ruler and the cylinder head.
Lock the high pressure fuel pump gear with a suitable rod.
Loosen the tension roller nut and remove the timing belt tension.
Caution: When turning the camshaft with the timing belt removed, none of the pistons should be in the top position. Otherwise, severe damage to the pistons or valves may occur.
If you need to turn the camshaft, first set all the pistons below dead centers. To do this, draw a chalk line on the top of the crankshaft belt pulley (condition: the crankshaft is in the top dead center position of the first cylinder), then turn the crankshaft pulley ¼ turn (90°) to the left or right. The chalk mark should now be facing right or left.
Loosen and remove the V-belt.
Remove the timing belt.
Installation
Check through the hole in the gearbox whether the TDC marks on the flywheel and the reference mark match.
Loosen the camshaft toothed pulley mounting bolt by ⅓ of a turn. Knock the toothed pulley off the camshaft cone using a hammer blow on a rod inserted into a 6 mm hole in the rear toothed belt cover.
Install the timing belt as shown in Figure 13-786 and remove the high pressure fuel pump gear retaining pin.
Tighten the timing belt.
Tighten the tension roller nut to 45 Nm.
Tighten the camshaft timing pulley mounting bolt to 45 Nm.
Remove the adjustment ruler.
Turn the crankshaft 2 revolutions in the direction of engine rotation. Hit with a rubber hammer between the toothed pulley of the camshaft and the gear of the high-pressure fuel pump and check again that the tension of the toothed belt corresponds to the specified value, if necessary, tighten the belt.
Check the moment the high pressure fuel pump starts supplying fuel.
Install the V-belt pulley and lower casing, tighten the V-belt.
Replace the cylinder head cover gaskets, tighten the cylinder head cover.
Install the upper timing belt cover.
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