Vanagon L4-1588cc 1.6L DSL SOHC (1983)
Diesel MFI Pump: Adjustments
Camshaft and Injection Pump Drive Belt
1.
Remove upper drive belt cover, then cylinder head valve cover.
2.
Disconnect wiring harness connectors to fuel shut-off solenoid.
3.
Rotate engine until cylinder No. 1 is at TDC. Do not rotate engine opposite normal direction of rotation (counterclockwise) using crankshaft
center bolt, as torque setting may be disturbed allowing sprocket to loosen.
Fig. 1 Camshaft locking tool installation
4.
Install camshaft locking tool No. 2065 or 2065A on rear of camshaft, Fig. 1. Center tool by inserting equal thickness shims between each side of
tool and cylinder head surface.
5.
Check that the timing marks on the sprocket, pump, and mounting plate are aligned. If they are not, loosen the camshaft sprocket 1 turn, tap the
sprocket until it is loose, then tighten the camshaft bolt until there is no freeplay but the sprocket still turns freely on the shaft.
6.
Loosen timing belt tensioner and remove belt. Do not rotate camshaft or crankshaft with belt removed, as engine damage will result.
7.
Turn the pump sprocket until locking pin 2064 can be inserted into the alignment holes.
8.
Install timing belt, tighten camshaft bolt to 33 ft. lbs. (45 Nm), then remove locking bar from rear of camshaft and locking pin from injection pump
sprocket.
Fig. 2 Timing belt tension tool installation
9.
Adjust belt tension by turning tensioner to right, and check tension as follows:
a. Install tension gauge VW 210 or equivalent, on belt between camshaft and injection pump, Fig. 2.
b. Adjust tension until gauge reads 12-13, then torque tensioner locknut to 33 ft. lbs. (45 Nm).
c. Rotate engine two complete turns clockwise, stopping with TDC mark on flywheel aligned with pointer.
d. Strike belt once with rubber mallet between camshaft and injection pump, then check tension with gauge.
10.
Check that injection pump timing is within specifications, then reverse procedure to complete installation.
