Timing Belt: Removal

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 alternator and remove V-belt. Remove crankshaft V-belt pulley. Remove air cleaner and ducting. Remove drive belt and cylinder head cover. Remove timing plug on top of bell housing. Rotate engine to bring No. 1 piston to TDC. Check that TDC mark on flywheel is aligned with reference.
Using locking tool (2065A for Vanagon, 2065 for other models) lock camshaft in position. Align tool by turning camshaft until one end of tool touches cylinder head. Measure gap at other end with feeler gauge. Insert feeler gauges of 1/2 thickness measured between tool and cylinder head at each end of tool. See Fig 1.
Lock injection pump sprocket at TDC with special pin (2064). See Fig 4. Loosen belt tensioner and remove timing belt from sprockets.

CAUTION: DO NOT TURN camshaft or crankshaft with drive belt removed.

Fig 1: Aligning Camshaft Locking Bar (2065A)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig 2: Drive Belt Tension Tester (VW 210)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig 3: Timing Mark (View Through Transmission)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig 4: Locking Injection Pump Sprocket (Lock Pin 2064)

Courtesy of VOLKSWAGEN UNITED STATES, INC.