Volkswagen Cars 2000-05

Distributor 2

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Removal & Installation





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Fig. Remove the distributor



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Fig. An additional mark is located on the crankshaft damper/pulley



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Fig. Checking Top Dead Center (TDC)

  1. On vehicles with manual transaxle, remove the plastic plug on the transaxle bell housing to view the timing marks on the flywheel.
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  3. Remove the upper timing belt cover. This is necessary to view the camshaft timing marks.
  4.  
  5. Unsnap the clips and remove the distributor cap and suppressor shield. It is not necessary to remove the spark plug wires from the distributor cap; position the cap and the attached wires aside. Unplug the Hall sensor connector on the side of the distributor.
  6.  


NOTE
Use caution when unplugging the hall sensor connector; the plastic socket is easily damaged.

  1. Using a breaker bar and an appropriate socket (usually 17mm) on the front crankshaft pulley bolt, turn the engine to Top Dead Center (TDC) on No. 1 piston. The No. 1 piston is at TDC on the compression stroke when the '0' mark on the flywheel and the marks on the camshaft align.
  2.  


NOTE
Less effort is required to turn the engine by hand if the spark plugs are removed.

  1. Verify that the timing is correct by checking that the rotor aligns with the No. 1 spark plug wire terminal. The No. 1 cylinder is closest to the camshaft and crankshaft pulleys.
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  3. On most distributors, there is an alignment notch on the rim of the distributor housing that aligns with the rotor when the No. 1 cylinder is at TDC. If not, make a mark on the distributor housing with a scribe or paint marker.
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  5. Next, mark the relationship of the distributor base to the engine block (or on 9A engines, the cylinder head) with a scribe or paint marker.
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  7. On 2.0L ABA engines, remove the single 13mm bolt, then lift off the holddown flange. Slowly lift the distributor straight out of the engine.
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NOTE
When the distributor is removed from the engine block, the rotor will turn slightly, this is due to the angled teeth on the distributor gear.

  1. On 2.0L 9A engines, remove the two 10mm mounting bolts and pull the distributor straight out of the cylinder head. Note which holes the bolts came from to make sure the timing can be adjusted correctly.
  2.  

To install:

  1. If the engine has been disturbed (rotated) since the distributor has been removed, proceed as follows:
  2.  
    1. Using a breaker bar and an appropriate socket (usually 17mm) on the front crankshaft pulley bolt, turn the engine to Top Dead Center (TDC) on No. 1 piston. The No. 1 piston is at TDC on the compression stroke when the '0' mark on the flywheel and the TDC marks on the camshaft align.
    2.  
    3. On 2.0L ABA engines, use a long flat-bladed screwdriver to turn the oil pump drive slot. On all engines except for the ACC, align the drive slot so it is parallel to the engine's crankshaft. On ACC engines, align the oil pump drive slot so it aligns with the distributor holddown bolt hole.
    4.  
    5. On 2.0L 9A engines, verify the position of the slot in the camshaft by looking through the distributor mounting hole in the cylinder head. With the marks on the distributor and the cylinder head aligned, install the distributor in the cylinder head.
    6.  

  3. While aligning the rotor with the mark on the rim of the distributor, and the marks on the engine block/cylinder head and distributor base, carefully mount the distributor to the engine.
  4.  


NOTE
On 2.0L ABA engines, remember that the curved gear teeth will cause the rotor to twist slightly when the distributor is installed. It may take a few attempts for everything to align properly.

  1. Install the distributor holddown bolt(s) and bracket (2.0L ABA only) and secure the distributor. Tighten the bolt(s) so the distributor can be rotated with moderate force. On ABA engines with locating pins in the distributor, this is not necessary, because the timing cannot be adjusted.
  2.  
  3. Plug in the Hall sensor plug on the side of the distributor, and position the distributor cap on the distributor and secure the spring clips.
  4.  
  5. Install the upper timing belt cover.
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  7. Adjust the 'base' timing as necessary.
  8.  

 
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