autotech 10.109.01.109 Manual Do Utilizador

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Installation Instructions

Alignment procedure for 4 cylinder Golf 3, Jetta 3, and Passat models

Caution:  Use the least amount of rotation necessary to align the crank/camshaft to their

respective markings.  Since the drive belt is not installed, there may be piston to valve inter-

ference if you try to rotate them too much.  If you have to rotate the camshaft a great

deal, make sure that there are no pistons at TDC before doing so.

1.  Set motor to TDC (see step 2 on instruction sheet).

2.  Loosen tension pulley and slide off camshaft drive belt.

3.  Align dot between the "O" and the "T" of the camshaft sprocket with the arrow on the

drive belt cover (fig. 1).

4.  Rotate crankshaft by hand until the TDC  mark on the flywheel lines up with the pointer

in the bellhousing (fig 2).

5.  Turn the intermediate shaft sprocket using the camshaft drive belt in direction of the

arrow (fig 3) until the distributor rotor lines up with the cylinder 1 marking on the distribu-

tor (fig 4).

6.  Slide camshaft drive belt over tension pulley and camshaft sprocket.

7.   Using a special spanner wrench (AST P/N 10.012.86400 or equiv.), tighten the drive belt

by rotating the tension pulley in the direction of the arrow (fig. 5). The belt should feel tight

when twisted 90 degrees with the thumb and forefinger, halfway between the camshaft and

intermediate shaft pulleys.  Tighten the pulley retaining nut to 33 ft/lb.

fig. 2

fig. 3

fig. 5

fig. 4

fig. 1