Toothed belt, removing and installing (engine codes AAZ up to 10.94, 1Z, AHU): Removing
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.
- Remove ribbed belt, see RIBBED BELT, REMOVING AND INSTALLING .
- Remove ribbed belt tensioning roller (if installed).
- Remove upper toothed belt guard and valve cover.
- Set crankshaft to TDC for cylinder 1 and lock camshaft using 2065A setting bar.
Center the 2065A setting bar as follows:
- Turn locked camshaft, with setting bar in place, until one end of setting bar touches cylinder head.
- Measure gap at other end of setting bar using feeler gauge.
- Select feeler gauge that is one half of measured gap, and temporarily install between setting bar and cylinder head.NOTE:
- Illustration shows engine code AAZ (3 mounting bolts)
- Engine codes 1Z, AHU uses a center mounting bolt.
- Turn camshaft so that setting bar is resting against feeler gauge then insert second feeler gauge of same thickness at other end between setting bar and cylinder head.
- Lock injection pump sprocket using lock pin.
- Engine code AAZ: 3359 rig pin
- Engine codes 1Z, AHU: 2064 lock pin
- Loosen injection pump sprocket mounting bolts -1- (AAZ) or center bolt (1Z, AHU).
- Loosen tensioner roller.
- Remove vibration damper and belt pulley.
- Remove lower toothed belt guard.
- Clearly identify toothed belt running direction using felt marker.
- Remove toothed belt.