Volkswagen Workshop Service and Repair Manuals

Special tools, testers, measuring instruments and auxiliary items required

• ◆ Setting bar 2065 A
• ◆ Pin 2064
• ◆ Pin wrench Matra V159
• ◆ Puller 3032
• ◆ Ring spanner 3035
• ◆ Torque wrench V.A.G 1331 (5...50 Nm)

Removing

• ‒ Remove air cleaner.
• ‒ Remove upper toothed belt guard.
• ‒ Remove cylinder head cover.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow-.
• ‒ Lock camshaft with setting bar.
• ‒ Centralize setting bar as follows:
  Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of same thickness, at the other end between setting bar and cylinder head.
• ‒ Remove idler roller.
• ‒ Release belt tension and take belt off camshaft and injection pump sprockets.
• ‒ Lock injection pump sprocket with pin 2064.
• ‒ Remove injection pump sprocket securing nut.

• ‒ → Loosen puller arms and offer up.
• ‒ Locate puller arms through holes in injection pump sprocket and tighten.
• ‒ Place injection pump sprocket under tension with puller.
• ‒ Release injection pump sprocket from injection pump taper by tapping on spindle of puller -arrow- (thereby hold sprocket so that it does not fall off).
• ‒ Remove all fuel pipes from pump and cover openings with clean cloth.

Note:

Use open ring spanner 3035 to remove high pressure fuel pipes.

• ‒ Disconnect fuel cut-off valve/commencement of injection valve connector.
• ‒ Disconnect quantity adjuster connector and unclip connector from retainer.
• ‒ → Remove securing bolts from console -arrows-.

• ‒ → Remove bolt from rear support -arrow-.
• ‒ Take off injection pump.

Installing

• ‒ Insert injection pump in console and then tighten securing bolt on rear support with conical nut first.
• ‒ Align injection pump to centre position of console elongated holes and secure hand tight.

Note:

The commencement of injection is set dynamically with V.A.G 1551.

• ‒ → Install injection pump sprocket and lock in position with pin 2064.
• ‒ When installing check woodruff key is correctly fitted.
• ‒ Tighten securing nut to 55 Nm.
• ‒ Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).
• ‒ Take off camshaft sprocket.
• ‒ Check whether TDC mark on flywheel and reference mark are aligned.
• ‒ Place toothed belt on injection pump sprocket and tensioning roller, place camshaft sprocket in toothed belt and fit to camshaft so that camshaft sprocket still turns.
• ‒ Install idler roller.
• ‒ Remove locking pin from injection pump sprocket.

• ‒ → Tension toothed belt. Using pin wrench (e.g. Matra V159) on eccentric turn clockwise until the notch and the raised mark -arrows- align.
• ‒ Tighten securing nut to 20 Nm.
• ‒ Check TDC mark on flywheel again.
• ‒ Tighten camshaft sprocket securing bolt to
  45 Nm.
• ‒ Remove setting bar 2065A from camshaft.
• ‒ Fill injection pump with clean Diesel through return pipe union. New pumps at least 180 ml.
• ‒ Reconnect injection pipes, fuel pipes and electrical wiring.
• ‒ Install toothed belt guard, cylinder head cover and air cleaner.
• ‒ Dynamically check and adjust commencement of injection
  =>Page 23-24 .