Volkswagen Golf/Jetta 2 manual

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


1 Fit the Woodruff key into its groove in the intermediate shaft then refit the sprocket to the front of the shaft. Locate the spacer washer onto the bolt then fit and tighten the bolt to the specified torque wrench setting.

Hold the sprocket stationary when tightening by inserting a screwdriver through one of its holes and jamming it against the cylinder block.

2 Locate the Woodruff key (if applicable) to the groove at the front of the crankshaft then refit the timing belt sprocket onto the shaft.

Lubricate the retaining bolt with oil, locate the spacer washer onto the bolt then fit and tighten it to the specified torque wrench setting. When tightening the bolt, prevent the crankshaft from turning by using the same method as that for its removal.

3 Locate the Woodruff key into its groove on the front of the camshaft then refit the camshaft sprocket. Refit the retaining bolt together with the spacer washer and tighten to the specified torque wrench setting. Hold the sprocket stationary when tightening by inserting a screwdriver through one of its holes and jamming it against the cylinder block or head.

4 If removed, refit the timing belt rear cover.

Apply locking compound to the stud thread.

5 Locate the crankshaft pulley onto the sprocket (aligning the marks made previously) using one bolt to secure it temporarily.

6 Turn the camshaft sprocket so that the lobes of No. 1 cylinder cams are pointing upwards and the mark on the camshaft sprocket is aligned with the valve cover - see illustration 9.7a.

7 Rotate the crankshaft sprocket and the intermediate shaft sprocket until the dot on the intermediate sprocket and the mark on the V-belt pulley coincide. Install the timing belt tensioner loosely and then the timing belt.

Making sure the marks are still in place, put a spanner on the adjuster and tighten the belt until it will twist only 90 degrees when held between the finger and thumb halfway between the camshaft and intermediate shaft sprockets. Tighten the eccentric adjuster nut to the specified torque - see illustration 9.8.

8 Unbolt and remove the crankshaft V-belt pulley.

9 Fit the lower timing cover then refit the crankshaft V-belt pulley and tighten its retaining bolts to the specified torque.

10 Locate the new valve cover gasket on the cylinder head, the seal to the No. 1 camshaft bearing cap and the half round grommet into its location at the rear end of the cylinder head.

11 Fit the valve cover into position, locate the reinforcement strips then refit and tighten the retaining nuts evenly to the specified torque.

12 Refit the upper timing belt cover.


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