Drive belt, removing, installing and adjusting tension: Installing

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CAUTION: Before turning camshaft, ensure that pistons are NOT at Top Dead Center (TDC). With the belt removed there is danger of damaging the valves and the piston crown.

Align marking on camshaft sprocket with marking on drive belt guard.

Fig 1: Aligning Camshaft Sprocket With Marking On Drive Belt Guard
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Install drive belt on crankshaft drive belt sprocket and on intermediate shaft drive belt sprocket (note running direction when installing a used belt).

NOTE: Disregard marking on intermediate shaft drive belt sprocket.

Install lower drive belt guard.
Install coolant pump pulley.
Install crankshaft vibration damper and pulley (note installation position, holes are offset).
Turn crankshaft to place the No. 1 cylinder at TDC. See THERMO TENSION ROLLER (1997), REMOVING AND INSTALLING .

Engine installed:

Turn flywheel -A- or driveplate -B- to align marks (arrows) and place No. 1 cylinder at TDC.

Fig 2: Aligning Flywheel/Driveplate Marks To Place No. 1 Cylinder At TDC
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Engine removed:

Turn crankshaft vibration damper to align notch with timing mark (arrow) and place No. 1 cylinder at TDC.

Fig 3: Aligning Crankshaft Vibration Damper Notch With Timing Mark
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Turn intermediate shaft drive belt sprocket with drive belt (in direction indicated by arrow) until distributor rotor aligns with marking for No. 1 cylinder on ignition distributor housing (drive belt slips over teeth of crankshaft drive belt sprocket).

Fig 4: Aligning Distributor Rotor With Marking For No. 1 Cylinder On Ignition Distributor Housing
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Marking for cylinder No. 1 on ignition distributor housing.

Install drive belt on tensioner and camshaft drive belt sprocket.

Fig 5: Installing Drive Belt On Tensioner And Camshaft Drive Belt Sprocket
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE: Tighten tensioner lock nut only slightly to make installation of the drive belt easier.

Increase tension on drive belt by turning tensioner pulley with wrench in direction shown (arrow).
- It must be possible to twist drive belt by 90° with thumb and forefinger half-way between camshaft and intermediate shaft drive belt sprockets.
Fig 6: Adjusting Tension On Camshaft Drive Belt
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Tighten lock nut on belt tensioner.
Tightening torque: 45 Nm (33 ft lb)
Turn crankshaft though two complete revolutions.
Check belt tension.
Check alignment of ignition distributor rotor with markings on distributor housing.
Install upper drive belt guard.
Install tensioner for ribbed belt.
Tightening torque: 20 Nm (15 ft lb)
Install ribbed belt. See RIBBED BELT, REMOVING AND INSTALLING .