Installing (adjusting valve timing)

NOTE:

The position of the toothed belt must be set as described below, even after repairs in which the belt is only taken off the camshaft sprocket.
When turning the camshaft the crankshaft must not be at TDC. Danger of damage valves/piston crown.

Fig 1: Setting Crankshaft To Markings For TDC Of No. 1 Cylinder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align camshaft sprocket mark with marking on cylinder head cover.
Place toothed belt on crankshaft sprocket (note direction of rotation).
Install toothed belt guard - lower part.
Install vibration damper (note installation position: hole in vibration damper is over projection on toothed belt sprocket).

Align vibration damper marking with marking on lower part of toothed belt guard.
Install toothed belt onto coolant pump, then tensioning roller, and finally camshaft sprocket.

Fig 2: Pulling Out Locking Pin, Loosening Piston Of Toothed Belt Tensioning Element & Removing Stud

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out locking pin (arrow) and loosen piston of toothed belt tensioning element. Remove stud -1-.
Turn crankshaft two complete turns in engine direction of rotation, set again to TDC and check adjustment.
Install engine support and console.
Remove engine support bracket 10-222 A with retainer 3180.

Install toothed belt guard (center and top sections).
Installing ribbed belt and tensioning element. Refer to Ribbed belt, removing and installing .
Install and secure coolant expansion tank and power steering reservoir.

Tightening torques

Component		Nm
Bottom section of toothed belt guard to cylinder block		10
Center section of toothed belt guard to cylinder block		10
Vibration damper to crankshaft		25
Engine support to cylinder block		45
Engine support to engine console 1)		60 + 90° 2)
Engine console to body 1)		40 + 90° 2)
Coolant expansion tank to body		10
Power assisted steering reservoir to body		10

1) stretch bolts - replace

2) 90° is a quarter turn