Removal
CAUTIONThe camshaft drive belt, the camshaft, and the cylinder head can be removed from the engine without first removing the engine from the vehicle. If the drive belt fails while the engine is running, it is likely that the valves, and possibly the pistons, will be damaged. Therefore, even though Volkswagen does not give a time or mileage at which the drive belt should be routinely replaced, the publisher recommends that the camshaft drive belt be replaced routinely each 48,000 to 80,000 km (30,000 to 50,000 mi.).
In replacing the drive belt, you do not need to remove the drive belt sprockets.
If crankshaft sprocket bolt becomes loose or is removed. on engines Code Letter CK, you should replace bolt and washer with new bolt (Part No. N 901 120 01) and new washer with collar (Part No. 068 105 299), then torque to 150 Nm (111 ft. lb.). If original bolt (Part No. 056 109 143) and flat washer (Part No. N 010 141 2) are used, apply Loctite 270 or 271 to threads.
REMOVING CAMSHAFT DRIVE BELT
View Of Timing Belt, Gears, And Pulleys:
1. Loosen the alternator mounting and adjusting bracket bolts. Push the alternator toward the engine. Then remove the alternator V-belt.
2. Take out the four socket-head bolts that hold the crankshaft pulley to the crankshaft sprocket. Then remove the pulley.
3. Detach the hoses from atop the drive belt cover. Remove the nuts and bolts that hold the drive belt cover, and remove the cover from the engine.
4. Remove the air cleaner, its duct, and the air filter.
5. Remove the eight bolts and the cylinder head cover retaining plates. Then carefully lift off the cylinder head cover and its gasket. If the gasket is stuck to the cylinder head, use a dull knife to separate the gasket from the head.
6. Remove the plug from the top of the flywheel bell-housing. Using a wrench on the crankshaft sprocket centerbolt, turn the crankshaft clockwise until the TDC mark on the flywheel is aligned with the pointer. Both valves for the No. 1 cylinder will be closed (cam lobes will be pointed upward).
Timing Mark Location:
7. Install special tool 2065 as illustrated. Then hand-turn the camshaft until one end of the special tool touches the cylinder head. Use a feeler gauge to measure the gap between the top of the cylinder head and the bottom of the side of the special tool that is not touching the cylinder head.
NOTE:
TDC marks aligned (arrow) in illustration. Special tool 2065 is used to lock camshaft in position.
8. Divide by 2 the measurement taken in step 7. Then, to lock the camshaft in position, insert a feeler gauge of this size on each side of the tool between the tool and the cylinder head.
Injection Pump Sprocket:
9. If the drive belt has neither broken nor jumped time, lock the injection pump sprocket in position as indicated. Otherwise, do not attempt to install the pin until you are ready to install the new drive belt. Injection pump sprocket is locked in position with special pin 2064.
NOTE:
If special pin 2064 fits easily into the holes in the pump sprocket and in the pump mounting bracket, the camshaft drive belt is correctly and accurately installed and the valve timing is correct.
10. Loosen the camshaft drive belt tension adjuster locknut. Using a wrench on the tension adjuster, turn the adjuster counterclockwise so that tension is removed from the drive belt. Then remove the drive belt. (Work it off the sprockets toward the right-hand side of the vehicle.)