Installing belt and adjusting tension (basic setting)
WARNING: This page is about a different car, the 1999 Volkswagen Jetta, 1998 Volkswagen Jetta, 1997 Volkswagen Jetta, 1996 Volkswagen Passat, and 1996 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
- Make sure that TDC marks on flywheel and references align.
- Loosen camshaft sprocket mounting bolt(s) 1/2 - turn.
- Loosen from tapered end of camshaft by very carefully tapping with hammer on soft drift inserted through hole of rear toothed belt guard or by GENTLY hitting sprocket squarely on sprocket teeth using synthetic face hammer.
- Place belt onto toothed belt sprocket/crankshaft, intermediate shaft sprocket, injection pump sprocket and tension roller.
Note running direction of belt.
- Place camshaft sprocket together with toothed belt and tighten mounting bolts.
Camshaft sprocket can still be turned.
- Turn tensioner roller to right using Matra V159 pin wrench (or equivalent) until notch and lifting arrow are across from one another.
- Tighten tensioner roller clamp nut.
Tightening torque: 20 Nm (15 ft lb)
NOTE: Fig 2 shows engine code 1Z; engine code AAZ is similar. - Make sure that TDC marks on flywheel and reference are still in alignment.
- Tighten camshaft sprocket mounting bolt.
Tightening torque: 45 Nm (33 ft lb)
- Tighten injection pump sprocket mounting bolt (s).
Tightening torque: 25 Nm (18 ft lb)
- Remove setting bar.
- Remove pin.
- Turn crankshaft twice in direction of rotation and place again at TDC for cylinder 1.