Beetle L4-1.9L DSL Turbo (ALH) (1998)
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Tension toothed belt; using pin wrench on eccentric, turn clockwise until notch and raised mark align -arrows-.
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Tighten lock nut on tensioning roller.
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Tightening torque: 20 Nm (15 ft lb)
Note:
Observe correct installation of tension roller in rear toothed belt guard -arrow-
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Check TDC mark on flywheel again.
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Tighten camshaft sprocket mounting bolt. 45 Nm (33 ft lb)
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Tighten the new mounting bolts of injection pump sprocket
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Tightening torque: 20 Nm (15 ft lb)
Notes:
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After dynamically testing the "start of injection" re-tighten the mounting bolts about 90° (1/4 turn.). Refer to: "Powertrain Management :
Diesel MFI Pump : Service and Repair" See: Powertrain Management/Fuel Delivery and Air Induction/Diesel MFI Pump/Service and
Repair
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The mounting bolts should only be used one time, since by design they have a reduced shank
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Remove 2065A setting bar from camshaft.
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Remove pin.
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Turn crankshaft two rotations in engine engine direction of rotation and set again to cylinder 1 TDC.
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Attach bracket to cylinder block.
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Install engine mount (replace mounting bolts).
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Tightening torque: 40 Nm (30 ft lb) + 90°(1/4 turn)
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Securely install mount for engine to engine bracket (replace mounting bolts)
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Tightening torque: 60 Nm (44 ft lb) + 90°(1/4 turn)
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Install bracket for subassembly/body
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Tightening torque: 25 Nm (18 ft lb)
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Install vacuum pump.
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Install toothed bell guard, vibration damper, belt pulley, and valve cover.
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Install ribbed belt. Refer to: "Engine : Drive Belt : Service and Repair" See: Ribbed Belt/Service and Repair
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Install sound dampening tray and engine cover.
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Remove pipe between charge air cooler and turbocharger. Refer to: "Powertrain Management : Turbocharger : Service and Repair" See:
Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair
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Install fuel filter with bracket
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Disconnect fuel supply and return lines at fuel filter.
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Install pipe between charge air cooler and intake pipe. Refer to: "Powertrain Management : Turbocharger : Service and Repair" See:
Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair
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Check Diesel injection pump. Refer to: "Powertrain Management : Diesel MFI Pump : Service and Repair" See: Powertrain
Management/Fuel Delivery and Air Induction/Diesel MFI Pump/Service and Repair