Volkswagen suggests checking the timing belt every 40,000 miles. Look for cracks in the ribs and for the proper tension. This determination is arrived at after an extensive study of the prior history of this engine. The 2.0 AEG is an interference-type engine. This is important because if it is not serviced properly and the belt comes off when the engine is running, disaster will most certainly strike. The valves will hit the pistons and destroy the motor. Close does not work on this engine. The timing marks must be perfect.
Instructions
- 1
Disconnect the battery negative terminal with a wrench. Raise the front of the Jetta and place a jack stand under the subframe on each side. Lower the car to rest on the stands. Remove the right front tire using the lug wrench to remove the lug nuts. Remove the inner splash shield using a socket.
2Remove the engine cover. Remove the serpentine belt using a wrench on the tensioner and then remove the automatic tensioner using a socket.
3Remove the upper timing belt cover using a 10 mm socket.
4Turn the crankshaft clockwise until the No. 1 cylinder is a top dead center (TDC) on the compression stroke. To determine this, the notch on the rear of the crankshaft pulley must line up with the mark on the block at precisely 12 o'clock or vertically and the timing mark in the hole in the top of the bell housing over the flexplate or flywheel must align. The manual transmission has a round hole with two facing arrows centered in the case. The notch next to a gear tooth on the flywheel must align with the arrows. The automatic transmission has a rectangular hole. The alignment mark is to the left or radiator side of the hole and the notch on the flexplate must align with the mark on the hole in the bell housing. If they crank and transmission marks do not align, turn the engine one more complete turn and they will align.
5Install the engine support and adapter over the strut towers.
6Remove the coolant reservoir with hoses attached and move it aside. Do the same to the power steering reservoir.
7Remove the crankshaft pulley bolts using a socket. Remove the crankshaft pulley. Remove the center and lower timing belt cover using a socket.
8Place the floor jack under the oil pan and raise the engine slightly. Remove the right hand square appearing engine mount by removing the center bolt and frame bolts with a socket.
9Loosen the nut on the timing belt tensioner and it will move away from the belt. Remove the belt.
10Check the timing marks before installing the belts. In addition to the aforementioned timing marks, check the camshaft sprocket alignment marks. At the 11 o'clock position there will be a notch on the sprocket and a hashmark on the rear cover with OT. Make sure these are perfectly aligned. Loosely install the timing belt by putting on only the crank and water pump sprockets.
11Install the right-hand engine mount to the engine with the single bolt. Install the lower and center timing belt cover.
12Install the crankshaft pulley and torque the bolts to 18 foot-pounds.
13Torque the bolts securing the engine mount to the bracket to 44 foot-pounds. Torque the long bolts to the body to 30 foot-pounds. Torque the short bolts to 18 foot-pounds.
14Install the timing belt over the tensioner pulley first followed by the camshaft sprocket. At this time adjust the timing belt teeth so all the slack in the belt is on the tensioner side of the engine. Keep it tight on the right side.
15Make sure that the tensioner retaining lug is in the slot in the cylinder head so it can't rotate when adjusted. Install the special tensioner wrench into the two holes in the tensioner pulley. Move the handle all the way to the right, then left lock to lock five times. Move the tensioner counterclockwise with the wrench until the pointer on the tensioner aligns with the V notch in the block. Torque the tensioner nut to 15 foot-pounds.
16Turn the crankshaft two complete turns clockwise and check to make certain that all three alignment marks are perfectly aligned. The last 45 degrees of rotation should be done without stopping. In addition, make sure tthe tensioner pointer is still aligned with the V notch in the block. Apply thumb pressure to the timing belt between the water pump pulley and the camshaft sprocket. While doing so, look at the tensioner pointer and make sure it moves away from the V notch when pressure is applied and returns when released.
17Turn the crankshaft two more times clockwise and check all alignment marks including the tensioner. Install the upper timing belt cover. Install the power steering reservoir and the coolant reservoir.
18Install the serpentine belt tensioner and the serpentine belt. Remove the engine support bracket. Install the inner splash cover. Install the negative battery cable.
