Volkswagen Golf/Jetta 2 manual

Timing belt and sprockets - removal
Engine repair procedures - 1.6 and 1.8 litre 8 valve / Timing belt and sprockets - removal


1 If the engine is still in the vehicle, first carry out the following operations: a) Disconnect the battery earth lead b) Remove the alternator drivebelt c) Unbolt and remove the coolant pump pulley
2 Depending on type, undo the retaining bolt(s)/nut(s), release the retaining clips and remove the upper timing cover (see illustration). On some engines it will be necessary to remove the bung from the front face of the cover to allow access to the Allen type retaining screw recessed within the cover. On other engines, the retaining screw can be seen but its key slot is deeply recessed (access to it being made via the hole in the centre of the screw surround).

9.2 Timing belt and cover components
9.2 Timing belt and cover components

3 Unscrew the nuts and bolts from the valve cover and remove the cover together with the gasket and reinforcement strips. Detach the crankcase emission hose(s) from the rocker cover.

4 Mark the relative positions of the crankshaft pulley and crankshaft sprocket, then undo the four socket-head bolts and withdraw the pulley.

5 Unbolt and withdraw the lower timing cover.

6 The engine must now be set for timing.

Temporarily refit the crankshaft pulley. On the intermediate sprocket for the timing belt one tooth has a centre-punch mark. Turn the engine until this mates with a notch on the V-belt pulley bolted to the crankshaft sprocket (see illustration). To turn the engine over, remove the spark plugs then fit a suitable spanner onto the crankshaft sprocket retaining bolt and turn it in the direction of engine rotation.

9.6 Intermediate sprocket timing mark (arrowed) aligned with notch in
9.6 Intermediate sprocket timing mark (arrowed) aligned with notch in crankshaft pulley

7 When these marks match, look at the sprocket on the camshaft. One tooth of this has a centre-punch mark. This should be level with the valve cover flange (see illustration).

Having turned the engine until these marks agree, now look at the cams for No 1 cylinder (nearest the timing belt). They will both be in the Сvalve closedТ position (see illustration).

Now look through the hole in which the TDC sensor goes where the timing marks show on the periphery of the flywheel and note the reading.

9.7a Camshaft sprocket timing mark (arrowed) with No 1 cylinder at TDC on
9.7a Camshaft sprocket timing mark (arrowed) with No 1 cylinder at TDC on compression

9.7b No. 1 cylinder cam lobes in valve closed positionv
9.7b No. 1 cylinder cam lobes in valve closed positionv

8 Before removing the timing drivebelt, check its correct tension. If held between the finger and thumb halfway between the intermediate shaft and the camshaft it should be just possible to twist it through 90∞ (see illustration). If it is too slack, adjust it by slackening the bolt holding the eccentric cam on the tensioner wheel. If you are satisfied it can be adjusted to the correct tension, remove it and examine it for wear. Now is the time to order a new one if necessary.

9.8 Timing belt tension check method
9.8 Timing belt tension check method

9 Loosen the tensioner then withdraw the timing belt from the camshaft, intermediate and crankshaft sprockets.

10 Each of the timing belt sprockets is secured by a central bolt and washer. The intermediate, camshaft and crankshaft sprocket (the latter in particular) securing bolts are tightened to a substantial torque and the sprockets will therefore need to be firmly held when undoing the bolts.

11 To remove the camshaft sprocket, unscrew the bolt with the sprocket held stationary by inserting a suitable metal bar through a sprocket hole and resting it on the valve cover face of the cylinder head, but take care not to damage the face. Remove the bolt and spacer washer then withdraw the sprocket, tapping it free if necessary. Check the fit of the Woodruff key in the camshaft, it must be renewed if loose in its groove. Lever out the Woodruff key and keep it with the sprocket.

12 To remove the crankshaft sprocket, hold the crankshaft stationary with a lever jammed in the starter ring gear (remove the starter motor as applicable). Do not allow the crankshaft to turn or the pistons may touch the valve heads. Unscrew the retaining bolt and remove it, together with the spacer washer, then lever the sprocket free from the crankshaft. Check the fit of the Woodruff key (if fitted) in the crankshaft, it must be renewed if loose in its groove. Lever out the Woodruff key and keep it with the crankshaft sprocket.

13 The intermediate shaft sprocket is removed in a similar manner to that for the camshaft sprocket.


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