5.4 Camshaft/Injection Pump Drive Belt

Although Volkswagen's maintenance schedule does not specify a replacement interval, the publisher recommends, as preventative maintenance, that the drive belt be inspected periodically and replaced every 60,000 to 75,000 miles (96,000 to 120,000 km) or 4 to 5 years. Removal of the belt is the best way to thoroughly inspect it, and is required for some repairs, such as injection pump or cylinder head removal. To simply replace the belt, the sprockets need not be removed.

Any time the camshaft drive belt is installed, camshaft timing and injection pump timing must be checked and adjusted. Some special tools are required.

To remove:

1.	Remove the upper drive belt cover. One bolt holds the cover on its mount. Three spring clips hold the upper cover to the rear drive belt cover. See Fig. 5-9.

2.	Remove the cylinder head cover and gaskets as described in ENGINE.

3.

Using a socket on the crankshaft pulley bolt, rotate the engine by hand to set the No.1 piston at Top Dead Center (TDC), and remove the pulley from the crankshaft. Check TDC removing the plug from the top of the fly-wheel bellhousing and aligning the marks on the fly-wheel, as shown in Fig. 5-10. Both valves for No. 1 cylinder should be closed (both cam lobes pointing approximately upward).

4.	Lock the camshaft in position. Fig. 5-11 illustrates the use of a Volkswagen special tool, no. 2065A, inserted in the slot at the end of the camshaft to hold it in position.

Fig. 5-9.

Camshaft and injection pump drive belt, sprockets, and covers.

Fig. 5-10.

Alignment of marks (arrow) indicating TDC.

Fig. 5-11.

Volkswagen special tool no. 2065A used to hold camshaft position. Shim tool at A and B with feeler gauges of equal thickness, until there is no play.

5.	Lock the injection pump in position. Insert a lock pin through the injection pump sprocket and the rear drive belt cover to keep the pump from turning, as shown in Fig. 5-12. If the drive belt is broken or has jumped time, do not attempt to lock the sprocket in position.

Fig. 5-12.

Injection pump sprocket locked in position with pin. Volkswagen special tool no. 2064 (order no. T02 064 000 00 ZEL) shown. Snug fit is required, allowing no movement.

6.	Loosen the coolant pump pulley bolts. Remove the V-belts as described in LUBRICATION AND MAINTENANCE. Remove the coolant pump pulley.

7.	Remove the two bolts and one nut holding the lower drive belt cover, then remove the cover.

8.	Loosen the camshaft drive belt tensioner's locknut. Turn the tensioner counterclockwise to remove tension from the belt, and remove the belt. Work it off the sprockets away from the engine.

9.	Temporarily tighten the tensioner locknut to inspect the tensioner. Check for smooth rotation and no play. Replace a worn tensioner.

10.	Inspect the drive belt for damage such as stretched cords, exposed threads, missing teeth, or other visible damage. Do not reinstall a worn or otherwise faulty belt.

11.	Inspect the area around the camshaft oil seal for leaks. If the seal is leaking, it is easiest to replace it before installing the camshaft drive belt. See ENGINE.

To install and adjust:

1.	If not done previously, set the crankshaft to TDC (No. 1 cylinder) and lock the camshaft and the injection pump at their TDC positions as described above under To remove:.

2.	Loosen the camshaft drive belt sprocket bolt 1/2 turn. Loosen the sprocket from the camshaft end by tapping the back side of the sprocket with a soft-faced hammer.

3.	Install the drive belt. There should be no slack between the camshaft sprocket and the injection pump sprocket, or between the injection pump sprocket and the crankshaft sprocket. Temporarily tighten the drive belt tensioner, just enough to keep the belt firmly in place.

4.	Remove the lock pin from the injection pump sprocket.

5.

Tension the drive belt. Loosen the tensioner locknut and turn the tensioner clockwise, using a spanner wrench as shown in Fig. 5-13. The tension gauge shown, Volkswagen special tool no. VW210 (order no. TV0 210 000 00 ZEL) should read between 12 and 13. Torque the tensioner locknut to 45 Nm (33 ft. lb.). Remove the belt tension gauge.

Fig. 5-13.

Spanner wrench (arrow) being used to adjust belt tension. Volkswagen special tool no. VW210 is belt tension gauge.

6.	Torque the camshaft sprocket bolt to 45 Nm (33 ft. lb.) and remove the locking tool from the camshaft.

7.	Turn the engine by hand, two full revolutions in the direction of crankshaft rotation (clockwise). Using a soft-faced hammer, strike the camshaft drive belt once, between the camshaft sprocket and the injection pump sprocket. Recheck drive belt tension and adjust if necessary.

8.	Check and adjust injection pump timing as described in

5.5 Injection Pump.