Removal and Installation

NOTE: The 8 valve engine requires a special wrench, Volkswagen No. US4493 or equivalent, to adjust the camshaft drive belt tensioner. Whenever the drive belt is removed and refitted, the camshaft and intermediate shaft timing MUST be adjusted. The drive belt can be replaced without removing the belt sprockets.

Exploded View Of Components:

1. Loosen alternator adjusting bolts and remove the fan belt.
2. Remove the water pump pulley bolts and remove the pulley.
3. Remove the upper timing cover bolts and remove the cover.
4. Remove the timing belt guide, if equipped.
5. Turn the engine by hand to set the No. 1 piston at Top Dead Center (TDC) and remove the crankshaft pulley.
6. Remove bolt and nuts securing the lower timing cover and remove the cover.

CAUTION: Turning the camshaft or crankshaft with the timing belt removed may cause damage to pistons and/or valves.

7. Loosen timing belt tensioner locknut, release belt tension and remove belt from sprockets.
8. Inspect belt for visible damage such as missing teeth or exposed threads. Inspect tensioner bearing for smooth running. Any damaged components should be replaced.

NOTE: On high mileage engines, failure of the tensioner bearing is a possibility. Consider replacing the bearing when replacing the timing belt.

Drive Belt Timing Marks - 8 Valve Engine:

9. Align the mark (can be a dot or notch) on the intermediate shaft sprocket with the notch in the crank pulley. Align the mark (can be a dot or notch) on the "Back" of camshaft sprocket with the top edge of the valve cover gasket. Be sure all the timing marks are properly aligned.
10. Temporarily install the crankshaft pulley to the crankshaft. Fit the timing belt starting with the crankshaft and intermediate shaft sprockets. Fit the belt so that it is as tight as possible between the crankshaft and the intermediate shaft sprockets and between the intermediate shaft and camshaft sprockets.

Checking Drive Belt Tension:

11. Turn the belt tensioner clockwise to adjust the tension. The direction is important to avoid contact with the timing cover. Check the tension by twisting the belt as shown. You should be able to twist it no more than 90 degrees.
12. Tighten the tensioner locknut to:

33 ft lbs (45 Nm)

13. Rotate the crankshaft two revolutions and recheck the belt tension and the timing marks for proper alignment.

NOTE: Very slight movement of sprockets and marks can be expected as belt tension is adjusted. Slight movement is OK. The smallest possible increment of adjustment is one whole tooth of the belt or sprocket.

14. Remove the crankshaft pulley and refit the lower timing cover. Tighten the bolts to:

87 in lbs (10 Nm)

15. Refit crankshaft pulley and tighten the bolts to:

15 ft lbs (20 Nm)

16. Refit timing belt guide, if equipped.
17. Refit upper timing cover and tighten bolt and nuts to:

87 in lbs (10 Nm)

18. Refit water pump pulley and tighten the bolts to:

15 ft lbs (20 Nm)

19. Refit fan belt and adjust tension. Tighten alternator adjusting bolts.