Volkswagen Golf / Golf GTI / Jetta. Manual — part 1233

- Open hose clamps - arrows - with Hose clip pliers V.A.G
1921/ and remove hose - 1 - .

- Loosen the fastening bolt for tensioner.

- Check the tensioner for damage and wear.

Note:

If any defects are determined, the toothed belt tensioner
must be replaced (repair measure).

- Tension the toothed belt. Turn the eccentric clockwise
with a commercially available hex key until the notch and
the marking tang, in the area of the protrusion of the
marking tang, align.

Note:

If the eccentric portion was turned too far once, the
tensioner must be completely relieved of tension and then
tensioned again. The eccentric portion should not be turned
to the position that was too far.

- Tighten the nut on the tensioner. Tightening torque: 20
Nm

Description of work (part 2 of 2)

13/2/2005

- Turn the crankshaft two revolutions in engine-turning
direction, until the crankshaft is at TDC for cylinder 1 -
arrow - .

Note:

When performing control and tuning work, under no
circumstances may the engine be turned over free of the
camshaft. Noncompliance may result in serious engine
damage.

- Lock the fuel injection pump wheel with the Alignment pin
for diesel injection pump VAS 3359 .

- Make sure again that the crankshaft is at TDC for cylinder
1.

- Remove the Alignment pin for diesel injection pump VAS
3359 from the fuel injection pump wheel.

Description of work (part 2 of 2)

13/2/2005

- Install hose - 1 - and secure with hose clamps - arrows - .

- Start engine and let run at idle for approx. 1 minute.

- Turn engine off.

- Verify again, that the notch - 1 - and the marking tang - 2 -
, in the area of the marking tang protrusion, are aligned. If
the notch and protrusion are not across from one another,
the tensioning procedure must be repeated.

- Install upper toothed belt cover.

Fuel filter, replacing (diesel engine)

Note:

Make sure that no diesel fuel gets onto the coolant hoses.
If necessary, clean hoses immediately!

Observe waste disposal regulations!

Perform the following work sequence:

Removing:

Description of work (part 2 of 2)

13/2/2005

- Remove the retaining clip - 1 - and remove regulator valve
- 2 - with attached fuel lines.

- Remove fuel line from hose connections - 3 - and - 4 - .

- Loosen the filter securing screw - arrow - and remove
filter upwards.

Installing:

- Install a new O-ring for the sealing of the regulating valve.

Note:

The direction of fuel flow is indicated with - arrows - on the
connections (do not switch connections).

- Fill new filter with diesel fuel. This way the engine can be
started faster.

Description of work (part 2 of 2)

13/2/2005