Volkswagen Cars 2000-05

Timing Belt 1

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General Information



Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain could last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valve train of an overhead camshaft engine.

Engines, chain or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing were disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time.

An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage:



Do you know if, or when, the belt was replaced-
 
If the vehicle is purchased used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect and replace as necessary
 
Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km) or every 6 years.
 


WARNING
Timing belt maintenance is extremely important! The A4 and Passat model utilize an interference-type, non-free-wheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. The recommended replacement interval for the timing belt is at least every 6 years or 60,000-90,000 miles (96,000-144,000 km), depending on vehicle usage and engine type.


NOTE
If the vehicle has been stored for long periods (2 years or more), the belt should be changed before returning the vehicle to service.


WARNING
NEVER allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.


NOTE
If removed and reinstalled, the timing belt must be installed in the same rotational direction as removed.

Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valvetrain of an overhead camshaft engine.

Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage:



Does the owner know if, or when the belt was replaced-
 
If the vehicle purchased is used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace or at least inform the owner that the vehicle is equipped with a timing belt.
 
Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).
 

Interference Engines

Engines, chain-or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing were disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time.

An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

Inspection




WARNING
Timing belt maintenance is extremely important! These models utilize an interference-type, non-free-wheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage.

All models covered herein, except the1993-97 Passat with the VR6 6-cylinder engine, use a toothed belt to drive the camshaft(s). This design is lightweight, and offers a low amount of parasitic drag on the crankshaft, which increases the output of the engine. Additionally, inspection and replacement of the belt is a relatively simple task (as opposed to replacing a timing chain and sprockets) ensuring that the engine is operating at its peak efficiency. On some models special tools may be required

The timing belt is a basic, yet critical engine component. If the belt were to break, the valve train can be seriously damaged. Frequent inspection, adjustment, and replacement of the timing belt and tensioning pulley is a must.

Audi and Volkswagen Do NOT list a replacement interval for timing belts for their later engines. Because of the consequences of a snapped timing belt (likely to result in significant engine damage), check the timing belt at regular intervals, and keep a record of the mileages checked.

On the 1990-93 2.0L 16-valve Passat GL/CL models, the timing belt should be checked every 2 years and replaced as necessary, or replaced every four years or (60,000 miles (96,000 km), whichever occurs first.

On all 1995-96 Passat GLS models, the timing belt and rollers should be inspected and adjusted as necessary at least every four years or every 60,000 miles (96,000 km) and replaced as necessary, especially on vehicles subjected to severe use. On all other models, if not replaced previously, replace the timing belt and rollers at 90,000 miles or every 6 years, whichever occurs first.

During inspection, check the belt for fluid contamination, cracking, damaged teeth and separation. If the belt is suspect in any of these areas replace the timing belt.



Click image to see an enlarged view

Fig. The timing belt on the right is beginning to crack and separate. The belt on the left could be reused if necessary. The belt on the right is ready to be replaced



Click image to see an enlarged view

Fig. The timing belt and tensioner assembly-1.8L engine shown

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist:



Hardening of the rubber-back side is glossy without resilience and leaves no indentation when pressed with a fingernail
 
Cracks on the rubber backing
 
Cracks or peeling of the canvas backing
 
Cracks on rib root
 
Cracks on belt sides
 
Missing teeth or chunks of teeth
 
Abnormal wear of belt sides-the sides are normal if they are sharp, as if cut by a knife.
 

If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.


WARNING
On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.


NOTE
For additional information, please refer to the following topic(s): General Information And Maintenance, Routine Maintenance And Tune-Up.



Click image to see an enlarged view

Fig. NEVER bend or twist a timing belt excessively, and Do NOT allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt



Click image to see an enlarged view

Fig. Broken tooth may be due to a damaged pulley



Click image to see an enlarged view

Fig. Back surface worn or cracked from a possible overheated engine or interference with the belt cover



Click image to see an enlarged view

Fig. Side wear from improper installation



Click image to see an enlarged view

Fig. Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt


NOTE
For manufacturers recommended service interval, refer to the maintenance interval chart located in this manual.

The average replacement interval for a timing belt is approximately 60,000 miles (96,000km). If, however, the timing belt is inspected earlier or more frequently than suggested, and shows signs of wear or defects, the belt should be replaced at that time.


WARNING
Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.



Click image to see an enlarged view

Fig. Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist:



Hardening of the rubber-back side is glossy without resilience and leaves no indentation when pressed with a fingernail
 
Cracks on the rubber backing
 
Cracks or peeling of the canvas backing
 
Cracks on rib root
 
Cracks on belt sides
 
Missing teeth or chunks of teeth
 
Abnormal wear of belt sides-the sides are normal if they are sharp, as if cut by a knife
 

If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.


WARNING
On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.



Click image to see an enlarged view

Fig. Broken tooth may be due to a damaged pulley



Click image to see an enlarged view

Fig. Back surface worn or cracked from a possible overheated engine or interference with the belt cover



Click image to see an enlarged view

Fig. Side wear from improper installation



Click image to see an enlarged view

Fig. Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt

Inspection & Adjustment



All 4-cylinder Volkswagen engines use a toothed belt to drive the camshaft(s). This design is lightweight, and offers a low amount of parasitic drag on the crankshaft, which increases the output of the engine. Additionally, inspection and replacement of the belt is a relatively simple task, (as opposed to replacing a timing chain and sprockets) ensuring that the engine is operating at its peak efficiency.

The timing belt is a basic, yet critical engine component. If the belt were to break, the valvetrain can be seriously damaged. Frequent inspection, adjustment, and replacement of the timing belt and tensioning pulley is a must.

Volkswagen specifies a 15,000 mile (24,000 km) inspection/adjustment interval of the timing belt. For 1997-99 TDI engines, a 10,000 mile (16,000 km) inspection/adjustment interval is specified.

Volkswagen does not list a replacement interval for timing belts for gasoline engines, but do specify a 60,000 mile (96,000 km) interval for diesel engines. It is highly recommended on all 4-cylinder engines that the timing belt be replaced at this 60,000 mile interval.

Please refer to Section 3 for procedures on timing belt adjustment, removal and installation.

Removal & Installation




WARNING
Do NOT turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.


NOTE
The radio may have a coded theft protection circuit. Obtain the code before disconnecting the battery, removing the radio fuse, or removing the radio.


CAUTION
Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.


CAUTION
On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

1.8L (Acc) And 2.0L (Aba) Engines

NOTE
Do not turn the engine or camshaft with the camshaft drive belt removed. The pistons will contact the valves and cause internal engine damage.

  1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s).
  2.  
  3. Temporarily reinstall the crankshaft pulley bolt, if removed, and turn the crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner drive belt cover, if equipped, or the edge of the cylinder head.
  4.  
  5. On 8-valve engines, the notch on the crankshaft pulley should align with the dot on the intermediate shaft sprocket. With the distributor cap removed, the rotor should be pointing toward the No. 1 mark on the rim of the distributor housing.
  6.  
  7. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt.
  8.  
  9. Slide the timing belt off the sprockets.
  10.  

To install:



Click image to see an enlarged view

Fig. Camshaft timing belt sprocket TDC alignment mark-Volkswagen 1.8L (ACC) and 2.0L (ABA) engines



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Fig. Align the flywheel (A) or driveplate (B) as shown for TDC alignment for cylinder No. 1-Volkswagen 1.8L (ACC) and 2.0L (ABA) engines



Click image to see an enlarged view

Fig. When the No. 1 cylinder is at TDC, the ignition rotor should face the notch in the distributor housing-Volkswagen 2.0L (ABA) engine

  1. Install the new timing belt and tension the belt so that it can be twisted 90 degrees at the middle of its longest section, between the camshaft and intermediate sprockets.
  2.  
  3. Recheck the alignment of the timing marks, if correct, turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck belt tension and timing marks. Readjust as required. Tighten the tensioner nut to 33 ft. lbs. (45 Nm).
  4.  
  5. Reinstall the belt cover and accessory drive belts.
  6.  


NOTE
When running the engine, there will be a growling noise that rises and falls with engine speed if the belt is too tight.


NOTE
Do not turn the engine or camshaft with the camshaft drive belt removed. The pistons will contact the valves and cause internal engine damage.

  1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s).
  2.  
  3. Temporarily reinstall the crankshaft pulley bolt, if removed, and turn the crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner drive belt cover, if equipped, or the edge of the cylinder head.
  4.  
  5. On 8-valve engines, the notch on the crankshaft pulley should align with the dot on the intermediate shaft sprocket. With the distributor cap removed, the rotor should be pointing toward the No. 1 mark on the rim of the distributor housing.
  6.  
  7. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt.
  8.  
  9. Slide the timing belt off the sprockets.
  10.  

To install:

Click image to see an enlarged view

Fig. Camshaft timing belt sprocket TDC alignment mark-Volkswagen 1.8L (ACC) and 2.0L (ABA) engines



Click image to see an enlarged view

Fig. Align the flywheel (A) or driveplate (B) as shown for TDC alignment for cylinder No. 1-Volkswagen 1.8L (ACC) and 2.0L (ABA) engines



Click image to see an enlarged view

Fig. When the No. 1 cylinder is at TDC, the ignition rotor should face the notch in the distributor housing-Volkswagen 2.0L (ABA) engine

  1. Install the new timing belt and tension the belt so that it can be twisted 90 degrees at the middle of its longest section, between the camshaft and intermediate sprockets.
  2.  
  3. Recheck the alignment of the timing marks, if correct, turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck belt tension and timing marks. Readjust as required. Tighten the tensioner nut to 33 ft. lbs. (45 Nm).
  4.  
  5. Reinstall the belt cover and accessory drive belts.
    NOTE
    When running the engine, there will be a growling noise that rises and falls with engine speed if the belt is too tight.

  6.  

1.8L (AEB) Engine
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the engine accessory drive belts. For additional information, please refer to the following topic(s): General Information And Maintenance, Routing Maintenance And Tune-up.
  6.  
  7. Using a 5 x 60mm bolt, secure the viscous fan pulley. Using a hex wrench, remove the viscous fan-to-pulley bolts. Remove the viscous fan assembly.
  8.  
  9. Turn the engine by hand to Top Dead Center (TDC) on the firing stroke for cylinder No. 1.
  10.  
  11. Remove the upper timing belt cover.
  12.  


NOTE
If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  1. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  2.  
  3. Remove the damper pulley-to-crankshaft bolts and the damper.
  4.  
  5. Remove the lower timing belt cover.
  6.  
  7. Using a Torx® Wrench T45, or equivalent, loosen the timing belt tensioner, push the tensioner downward and remove the timing belt.
  8.  



Click image to see an enlarged view

Fig. Crankshaft pulley and camshaft sprocket alignment locations-1.8L engine



Click image to see an enlarged view

Fig. Timing belt tension adjustment-1.8L engine



Click image to see an enlarged view

Fig. Timing belt tension wear limits-1.8L engine



Click image to see an enlarged view

Fig. The Top Dead Center (TDC) alignment marks for the camshaft sprocket



Click image to see an enlarged view

Fig. The timing belt, tensioner and guide roller

To install:

  1. Align the camshaft sprocket timing mark with the cylinder head cover mark.
  2.  
  3. Install the timing belt on the crankshaft sprocket with the arrow facing the rotational direction.
  4.  
  5. Install the lower timing belt cover.
  6.  
  7. Using a bolt, secure the damper/belt pulley on the crankshaft.
  8.  
  9. Align the crankshaft damper/belt pulley with the housing timing mark so that the No. 1 cylinder is at TDC of its compression stroke.
  10.  
  11. Install the timing belt on the camshaft sprocket and belt tensioner.
  12.  
  13. Using a 2-pin Spanner Matra Tool No. V159 Wrench, or equivalent, lift (turn clockwise) the timing belt tensioner cylinder No. 1 until it is fully extended and tensioner cylinder No. 2 is raised approx. 1mm ( 3 / 8 inch); then, hand-tighten the mounting bolt.
  14.  
  15. Rotate the crankshaft 2 complete rotation in the running direction.
  16.  
  17. Inspect area 'A' for proper alignment with the upper edge of piston No. 2 and adjust if necessary.
  18.  


    Area 'A' - adjustment OK
     
    Area 'B' - wear limit
     
    Area 'C' - re-adjust and check belt drive including tensioner for wear.
     



NOTE
If the piston edge is located in area 'A', measurement 'D' is 25-29mm ( 31 / 32 -1 1 / 8 inches).

  1. After adjustment has been verified, secure the tensioner with a 2-pin Spanner Matra Tool No. V159 Wrench, or equivalent, and tighten the mounting bolt.
  2.  
  3. Complete the damper to crankshaft installation.
  4.  
  5. Using the center bolt, rotate the crankshaft 2 rotations in the direction of engine rotation until the camshaft and crankshaft marks align with their respective reference points.
  6.  
  7. Install the upper timing belt cover.
  8.  
  9. Install the drive belts.
  10.  
  11. The balance of assembly is in reverse order of removal.
  12.  
  13. Install the negative battery cable last.
  14.  
  15. Test drive the vehicle.
  16.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the necessary components to gain access to the front of the engine.
  4.  
  5. Place an open-end wrench on the alternator belt tensioner and rotate it clockwise toward the alternator to release the belt-s tension. Remove the alternator serpentine drive belt and release the tensioner.
    NOTE
    If necessary to lock the alternator tensioner in position, align the housing holes and insert an Allen wrench into the holes to secure its movement.

  6.  
  7. Using a 5 x 60mm bolt, secure the viscous fan pulley. Using a hex wrench, remove the viscous fan-to-pulley bolts. Remove the viscous fan assembly.
  8.  
  9. Remove the upper timing belt cover.
    NOTE
    If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  10.  
  11. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  12.  
  13. Remove the damper pulley-to-crankshaft bolts and the damper.
  14.  
  15. Remove the lower timing belt cover.
  16.  
  17. Using a Torx Wrench T45, loosen the timing belt tensioner, push the tensioner downward and remove the timing belt.

    Click image to see an enlarged view

    Fig. Crankshaft pulley and camshaft sprocket alignment locations-Volkswagen 1.8L (AEB) 4-Cyl engine



    Click image to see an enlarged view

    Fig. Timing belt tension adjustment- Volkswagen 1.8L (AEB) 4-Cyl engine



    Click image to see an enlarged view

    Fig. Timing belt tension wear limits- Volkswagen 1.8L (AEB) 4-Cyl engine

  18.  

To install:

  1. Align the camshaft sprocket timing mark with the cylinder head cover mark.
  2.  
  3. Install the timing belt on the crankshaft sprocket with the arrow facing the rotational direction.
  4.  
  5. Install the lower timing belt cover.
  6.  
  7. Using a bolt, secure the damper/belt pulley on the crankshaft.
  8.  
  9. Align the crankshaft damper/belt pulley with the housing timing mark so that the No. 1 cylinder is at TDC of its compression stroke.
  10.  
  11. Install the timing belt on the camshaft sprocket and belt tensioner.
  12.  
  13. Using a 2-pin Spanner Matra V159 Wrench, lift (turn clockwise) the timing belt tensioner cylinder No. 1 until it is fully extended and tensioner cylinder No. 2 is raised approx. 1mm; then, hand-tighten the mounting bolt.
  14.  
  15. Rotate the crankshaft 2 complete rotation in the running direction.
  16.  
  17. Inspect area -A- for proper alignment with the upper edge of piston No. 2 and adjust if necessary.
    NOTE
    If the piston edge is located in area -A-, measurement -D- is 0.984-1.142 in. (25-29mm).



    Area -A- - adjustment OK
     
    Area -B- - wear limit
     
    Area -C- - re-adjust and check belt drive including tensioner for wear.
     

  18.  
  19. After adjustment has been verified, secure the tensioner with a 2-pin Spanner Matra V159 Wrench and tighten the mounting bolt.
  20.  
  21. Complete the damper to crankshaft installation.
  22.  
  23. Using the center bolt, rotate the crankshaft 2 rotations in the direction of engine rotation until the camshaft and crankshaft marks align with their respective reference points.
  24.  
  25. Install the upper timing belt cover.
  26.  
  27. Install the drive belts.
  28.  
  29. Replace the remaining components by reversing the removal procedures.
  30.  
  31. Install the negative battery cable last.
  32.  
  33. Test drive the vehicle.
  34.  

1.8L (Aeb/Atw/Awm/Awv) 4-Cylinder Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the necessary components to gain access to the front of the engine.
  4.  
  5. Place an open-end wrench on the alternator belt tensioner and rotate it clockwise toward the alternator to release the belt-s tension. Remove the alternator serpentine drive belt and release the tensioner.
  6.  


NOTE
If necessary to lock the alternator tensioner in position, align the housing holes and insert an Allen wrench into the holes to secure its movement.

  1. Using a 5 x 60mm bolt, secure the viscous fan pulley. Using a hex wrench, remove the viscous fan-to-pulley bolts. Remove the viscous fan assembly.
  2.  
  3. Remove the upper timing belt cover.
  4.  


NOTE
If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  1. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  2.  
  3. Remove the damper pulley-to-crankshaft bolts and the damper.
  4.  
  5. Remove the lower timing belt cover.
  6.  
  7. Using a Torx Wrench T45, loosen the timing belt tensioner, push the tensioner downward and remove the timing belt.
  8.  


    Click image to see an enlarged view

    Fig. Crankshaft pulley and camshaft sprocket alignment locations-Volkswagen 1.8L (AEB/ATW/AWM/AWP/AWV/AWW) 4-Cyl engine



    Click image to see an enlarged view

    Fig. Timing belt tension adjustment- Volkswagen 1.8L (AEB/ATW/AWM/AWV) 4-Cyl engine



    Click image to see an enlarged view

    Fig. Timing belt tension wear limits- Volkswagen 1.8L (AEB/ATW/AWM/AWV) 4-Cyl engine


To install:

  1. Align the camshaft sprocket timing mark with the cylinder head cover mark.
  2.  
  3. Install the timing belt on the crankshaft sprocket with the arrow facing the rotational direction.
  4.  
  5. Install the lower timing belt cover.
  6.  
  7. Using a bolt, secure the damper/belt pulley on the crankshaft.
  8.  
  9. Align the crankshaft damper/belt pulley with the housing timing mark so that the No. 1 cylinder is at TDC of its compression stroke.
  10.  
  11. Install the timing belt on the camshaft sprocket and belt tensioner.
  12.  
  13. Using a 2-pin Spanner Matra V159 Wrench, lift (turn clockwise) the timing belt tensioner cylinder No. 1 until it is fully extended and tensioner cylinder No. 2 is raised approx. 1mm; then, hand-tighten the mounting bolt.
  14.  
  15. Rotate the crankshaft 2 complete rotation in the running direction.
  16.  
  17. Inspect area -A- for proper alignment with the upper edge of piston No. 2 and adjust if necessary.

    Area -A- - adjustment OK
     
    Area -B- - wear limit
     
    Area -C- - re-adjust and check belt drive including tensioner for wear.
     

  18.  


NOTE
If the piston edge is located in area -A-, measurement -D- is 0.984-1.142 in. (25-29mm).

  1. After adjustment has been verified, secure the tensioner with a 2-pin Spanner Matra V159 Wrench and tighten the mounting bolt.
  2.  
  3. Complete the damper to crankshaft installation.
  4.  
  5. Using the center bolt, rotate the crankshaft 2 rotations in the direction of engine rotation until the camshaft and crankshaft marks align with their respective reference points.
  6.  
  7. Install the upper timing belt cover.
  8.  
  9. Install the drive belts.
  10.  
  11. Replace the remaining components by reversing the removal procedures.
  12.  
  13. Install the negative battery cable last.
  14.  
  15. Test drive the vehicle.
  16.  

 
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