Installation

TO INSTALL AND ADJUST:

CAUTION: Rotating the crankshaft or the camshaft with the drive belt removed may cause interference which can damage pistons and valves.

Camshaft Drive Belt & Cover:

1. Loosely install the drive belt over the crankshaft and intermediate shaft sprockets.
2. Install the lower drive belt cover and the crankshaft vibration damper.

Tightening Torques:
Cover (bolt and nuts): 10 Nm (89 in lb)
Vibration damper: 20 Nm (15 ft lb)

Camshaft Timing Marks:

3. Slowly rotate the camshaft to align the timing marks. Camshaft timing marks align with cylinder head cover (left) or top surface of cylinder head (right).

Crankshaft Timing Marks:

4. Rotate the crankshaft to bring the #1 cylinder to top dead center (TDC). Align the vibration damper and flywheel timing marks as shown. Crankshaft timing marks (arrows). With engine out of car use marks on vibration damper and lower drive belt cover (left). With engine in car use #1 cylinder TDC mark on flywheel (right).

NOTE: The intermediate shaft does not require timing or alignment.

5. Mount the drive belt on the camshaft sprocket. Match the belt to the sprocket teeth so that there is as little slack as possible between the crankshaft and the intermediate shaft sprockets, and between the intermediate shaft and the camshaft sprockets.
6. Tighten the belt. Turn the tensioner clockwise until the belt has the proper tension, then secure it with the locknut.
7. Check belt tension:

Tensioning Camshaft Drive Belt Using VW Special Tool 210:

- Using Volkswagen special tool VW 210. Note, pins in spanner wrench (arrow) engage holes in tensioner.

Tensioning Camshaft Drive Belt:

- By twisting the belt. Check by twisting belt halfway between camshaft and intermediate shaft sprockets. Inset shows spanner wrench used on Passat. Engine shown is from another Volkswagen model.

Drive Belt Tension Specifications:
Scale reading (VW 210): 13 to 14
By hand: when maximum twist = 45°

Tightening Torque:
Tensioner locknut: 45 Nm (33 ft lb)

8. Rotate the crankshaft by hand for two complete revolutions, then recheck the belt tension and the timing marks.

NOTE: Some movement of the sprockets and timing marks as belt tension is adjusted is normal. Note that the smallest possible increment of adjustment (or misadjustment) is one whole tooth.

9. Remaining installation is the reverse of removal. Install and tension the V-belts.

Tightening Torques:
Upper belt cover (bolt): 6 Nm (53 in lb)
Coolant pump pulley (bolts): 20 Nm (15 ft lb)