Distributor: Service and Repair

DISTRIBUTOR, REMOVING AND INSTALLING

Special tools, testers and auxiliary items
- Pin wrench Matra V159
- Torque wrench VAG 1331 (5-50 Nm)

NOTE: The Motronic Engine Control Module (ECM) requires the Cyl. 1 TDC signal from the camshaft position sensor in the distributor in order to allocate the fuel injection and knock sensor systems according to the firing order.

Checking Cyl.1 Top Dead Center (TDC) markings





- Set flywheel -A- or automatic transmission drive plate -B- to align marks for Cyl.1 TDC.

Engine removed





- Set vibration damper (V-belt pulley) to mark for Cyl.1 TDC.





- Mark on camshaft sprocket must align with arrow on cylinder head cover.





- Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover.

Removing
- Crankshaft and camshaft in Cyl.1 TDC position
- Remove distributor.

Installing





- Align oil pump shaft drive lug parallel to crankshaft.





- Install distributor.
- Pins on distributor must point toward mounting bolt threaded hole (arrow).

NOTE: When installing, turn the rotor arm slightly the the right of the distributor marking (clockwise). When inserting the distributor and meshing the drive gears, the rotor arm will turn back toward the marking.





- Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover.
- Tighten distributor securing bolt.

Tightening torque: 25 Nm (18 ft lb)

If the markings cannot be aligned correctly:
- Loosen toothed drive belt tensioner roller and remove toothed belt from camshaft sprocket.





Turn intermediate shaft sprocket with toothed drive belt (in direction of arrows) until rotor arm aligns with markings for Cyl.1 on distributor housing.
(Toothed belt slides over crankshaft sprocket.)





- Mark on distributor housing must align with mark on rotor arm or camshaft position sensor cover.
- Position toothed drive belt onto tensioner roller and camshaft sprocket.

NOTE: For easier installation of the toothed belt, loosen the tensioner roller lock nut by only approx. one thread.





- Turn tensioner with pin wrench (e.g. Matra V159) in direction of arrow to adjust toothed drive belt tension.
- It must be just possible to turn the toothed belt through 90° with the thumb and forefinger in the center between camshaft and intermediate shaft sprockets.
- Tighten tensioner lock nut.

Tightening torque: 45 Nm (33 ft lb)

- Rotate crankshaft two full turns and check adjustment.
- Check distributor housing and rotor arm markings.
- Install upper toothed drive belt cover.
- Before installing, clean distributor cap, check for cracks and signs of tracking, and replace if necessary.