|
|
|
Content .. 1714 1715 1716 1717 ..
1. Ensure cylinder No. 1 is at TDC. Check reference mark on flywheel and bellhousing. See Fig. 1 . 2. Using Spanner Wrench (3036) counter-hold camshaft and loosen camshaft sprocket bolt 1/2 turn. See 3. Install timing belt onto crankshaft sprocket, idler pulley, water pump, injection pump sprocket, and tensioner pulley. Adjust injection pump sprocket on mount so mounting slots are centered. If installing 4. Install camshaft sprocket together with timing belt. Install camshaft sprocket bolt finger tight. Camshaft sprocket should still be free to turn. 5. On Golf and Jetta with automatic transaxle, use an Allen wrench to turn timing belt tensioner clockwise until notch and pointer align. See Fig. 5 . If tensioner is turned too far and correct tension is exceeded, 6. On Golf and Jetta with manual transaxle and New Beetle, install Tension Pin Wrench (MATRA V159) on timing belt tensioner pulley. See Fig. 6 . Turn wrench clockwise until notch and raised mark are aligned. 7. On all models, ensure tensioner is correctly installed in rear timing belt cover. See Fig. 7 . Ensure TDC marks on flywheel are still aligned. Using Spanner Wrench (3036) counter-hold camshaft and tighten 8. Install NEW torque-to-yield mounting bolts in diesel injection pump sprocket. Tighten injection pump bolts to 15 ft. lbs. (20 N.m). Before final tightening of injection pump mounting bolts, perform start of 9. Remove camshaft setting bar from rear of camshaft. Remove lock pin from injection pump. 10. Rotate crankshaft 2 complete revolutions. Place crankshaft at TDC and ensure belt timing is correct. Ensure timing belt tensioner pulley marks are still aligned. 11. To complete installation, reverse removal procedure. When installing engine mount, install mounting bolts in holes on bracket before attempting to fit bracket to engine block. Tighten nuts and bolts to 12. Using scan tester (VAG 1551/1552), check Diesel injection pump start of delivery. NOTE: Timing belt installation procedure requires using a factory scan tester (VAG CAUTION: Use Spanner Wrench (3036) to hold camshaft sprocket while loosening and tightening camshaft sprocket bolt. DO NOT use
2003 Volkswagen New Beetle GLS VOLKSWAGEN 1.9L 4-Cylinder - Turbo Diesel - ALH Engine
Helpmelearn Repair Manuals
Wednesday, December 14, 2005 8:41:00 AM Page 7 © 2004 Mitchell Repair Information Company, LLC. |