Removal (4-Cyl. Engine)
WARNING: This page is about a different car, the 1983 Volkswagen Vanagon, 1983 Volkswagen Rabbit, 1983 Volkswagen Quantum, 1983 Volkswagen Pickup, and 1983 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
- Loosen and remove alternator belt. Remove crankshaft pulley bolts and pulley. Detach hoses from drive belt cover, then remove cover bolts and cover.NOTE: It is not necessary to remove the timing belt sprockets when removing injection pump belt from the engine.
- Remove air cleaner, duct, and valve cover. Remove the timing mark plug from the top of the bellhousing. Use bolt in center of crankshaft sprocket to rotate engine. Align TDC mark on flywheel with pointer. Check that both cam lobes on No. 1 cylinder are pointing up.
- Install special setting bar (2065) in slot in the end of he camshaft. Rotate the camshaft by hand until one end of the bar touches the cylinder head. Measure the gap at the other end of the bar with a feeler gauge and divide this number by 2. Use 2 feeler gauges of this size; they will be necessary to lock camshaft on center.
- Lock camshaft in position by inserting one feeler gauge on either side of the bar, between the bar and the cylinder head. Loosen camshaft drive belt tensioner lock nut and turn tensioner counterclockwise to remove tension from belt. Remove the belt by working it off the sprockets.