Timing Belt: Service and Repair

1. Remove battery ground cable.

Camshaft Timing Mark:

2. Bring no. 1 cylinder to top dead center on the compression stroke. Check that the mark (can be dot or notch) on the "Back" of the camshaft sprocket is aligned with the upper edge of the valve cover gasket.

Flywheel Mark Alignment:

The flywheel mark "O" should be aligned with the cast mark of the bellhousing.
3. Remove the drive belts from the power steering, alternator and A/C compressor.
4. If necessary, remove the power steering pump mounting bolts and position the pump aside with the hoses attached.
5. Remove the upper and lower timing belt covers.

Tool #2084 Installed:

Tool #2079 Installed:

CAUTION: Do not pinch the drive belt between the oil pump housing and belt sprocket.

6. To loosen the front crankshaft damper bolt, use Volkswagen tool No. 2084 (or equivalent) to hold the crankshaft in position and Volkswagen extention tool No. 2079 (or equivalent) with a suitable ratchet, to break the bolt loose. DO NOT REMOVE the bolt at this time.
7. Remove the upper radiator cover.
8. Loosen the water pump retaining bolts and turn the pump in a clockwise direction to relieve the tension on the timing belt. (Insert a suitable pry bar or screwdriver through the hole in the radiator side cover to turn the pump.)

NOTE: There is a possibility that the water pump may leak if the pump o-ring is not replaced.

9. Remove the timing belt from the camshaft sprocket.
10. Remove the front crankshaft bolt, damper, and belt.
11. Be sure that the camshaft and flywheel marks are aligned as in step 2.

Exploded View Of Components:

12. Position the timing belt on the crankshaft damper.
13. Fit the damper, with the belt, to the crankshaft. Be sure to align the damper keyway with the crankshaft key. Also be sure that the timing belt teeth are seated correctly in the sprocket groves.
14. Coat the threads of the crankshaft bolt with a suitable thread locking compound and install it in the crankshaft.
15. Position the timing belt over the camshaft and water pump sprockets.
16. Use Volkswagen tool No. 2084 (or equivalent) to hold the crankshaft in position and tighten the damper bolt with Volkswagen extention tool No. 2079 (or equivalent) and a suitable torque wrench.

CAUTION: Tightening torque applies only when the extention tool is used in alignment with torque wrench.

Retaining bolt torque 258 ft lbs

17. Recheck camshaft and flywheel marks for proper alignment as in step 2.
18. Adjust the timing belt tension by rotating the water pump upward (counter-clockwise), using a suitable pry bar or screwdriver through the hole in the radiator side cover to turn the pump. Tighten the pump retaining bolts. Check the water pump for leaks.

Water Pump Bolt Torque 15 ft lbs (20 Nm)

Checking Belt Tension:

19. The timing belt is properly tensioned when it can be twisted 90 degrees at the midway point between the camshaft and water pump sprockets. Grasp the belt as shown, when checking the tension.
20. Refit the upper radiator cover.
21. Refit the lower and upper timing belt covers.

Timing Cover Bolt Torque 7 ft lbs (10 Nm)

22. Refit the power steering pump, if removed.
23. Refit the drive belts for the power steering, alternator and A/C compressor.
24. Reconnect the battery ground cable.
25. Check the ignition timing and adjust as necessary.