Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Lever 3297 (for ribbed belt drive without tensioning roller).
• ◆ Lever 3299 (for ribbed belt drive with tensioning roller).
• ◆ Setting bar 2065 A
• ◆ Pin 2064 (for single part injection pump sprocket)
• ◆ Pin 3359 (for two part injection pump sprocket)
• ◆ Pin wrench Matra V159
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)

Engines without semi-automatic tensioning roller:

• ◆ V- and toothed belt test unit VW 210

Belt drive with single part injection pump sprocket

Belt drive with two part injection pump sprocket

Removing

• ‒ Remove ribbed belt .
• ‒ If fitted remove ribbed belt tensioning roller.
• ‒ Remove upper toothed belt guard and 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.

• ‒ → Lock injection pump sprocket with pin.
• ‒ Loosen tensioner.
• ‒ Remove vibration damper and belt pulley.
• ‒ Remove lower toothed belt guard.
• ‒ Mark D.O.R. of toothed belt.

Engines with semi-automatic tensioning roller:

• ‒ Remove idler roller.

• ‒ Take off toothed belt.

Installing

• ‒ Check whether TDC mark on flywheel and reference mark are aligned.
• ‒ 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).

Engines without semi-automatic tensioning roller:

• ‒ → Fit toothed belts (note D.O.R.) and remove pin from fuel injection pump sprocket.
• ‒ Tension toothed belts (turn tensioner with pin wrench e.g. Matra V159 -arrow- to right).
       Scale value: 12 ... 13
  measured between camshaft sprocket and injection pump sprocket.
• ‒ Tighten lock nut on the tensioner.
       Tightening torque: 45 Nm
• ‒ Tighten camshaft sprocket securing bolt to
  45 Nm.
• ‒ Remove setting bar.
• ‒ Turn crankshaft two rotations in engine D.O.R. and again check toothed belt tension.

Engines with semi-automatic tensioning roller:

• ‒ Fit toothed belt (note direction of rotation) and remove pin from injection pump sprocket.
• ‒ Install idler roller.
       Tightening torque: 25 Nm

• ‒ → Turn tensioning roller with pin wrench (e.g. Matra V159) to right until notch aligns with raised portion (arrows).
• ‒ Tighten lock nut on tensioning roller.
       Tightening torque: 20 Nm
• ‒ Check again whether TDC mark on flywheel and reference mark are aligned.
• ‒ Tighten camshaft sprocket securing bolt to
  45 Nm.
• ‒ Remove setting bar.

Continuation for all engines

• ‒ Install toothed belt guard, vibration damper, belt pulley, and cylinder head cover.
• ‒ Install ribbed belt => Page 13-16 .

Engine codes 1Z, AHU, AFN

• ‒ Checking injection pump commencement of delivery:

=> Repair group 23; Servicing Diesel direct injection system; Dynamically checking and adjusting injection pump commencement of delivery.

Engine code AAZ

• ‒ Check injection pump commencement of delivery:

=> Repair group 23; Servicing Diesel injection system; Checking and adjusting injection pump commencement of delivery (static).

Belt drive with two part injection pump sprocket

Removing

• ‒ Remove ribbed belt => Page 13-16 .
• ‒ If fitted remove ribbed belt tensioning roller.
• ‒ Remove upper toothed belt guard and 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.

• ‒ → Lock injection pump sprocket with pin 3359.
• ‒ Loosen injection pump sprocket securing bolts -1-.
• ‒ Loosen tensioner.
• ‒ Remove vibration damper and belt pulley.
• ‒ Remove lower toothed belt guard.
• ‒ Mark D.O.R. of toothed belt.
• ‒ Take off toothed belt.

Installing

• ‒ Check whether TDC mark on flywheel and reference mark are aligned.
• ‒ → 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).
• ‒ Fit toothed belts (note D.O.R.) on crankshaft toothed belt sprocket, intermediate wheel, injection pump sprocket and tensioning roller.
• ‒ Fit camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still turn).

• ‒ → Turn tensioning roller with pin wrench (e.g. Matra V159) to right until notch aligns with raised portion (arrows).
• ‒ Tighten lock nut on tensioning roller.
       Tightening torque: 20 Nm
• ‒ Check again whether TDC mark on flywheel and reference mark are aligned.
• ‒ Tighten camshaft sprocket securing bolt to
  45 Nm.
• ‒ Tighten injection pump sprocket securing bolts to
       25 Nm.
• ‒ Remove setting bar.
• ‒ Remove pin.
• ‒ Turn crankshaft two rotations in engine D.O.R. and set again to TDC No. 1 cylinder.

• ‒ → Check whether injection pump sprocket can be locked with pin 3359.

If the injection pump sprocket cannot be locked:

• ‒ Loosen injection pump securing bolts -1-.
• ‒ Turn injection pump sprocket hub until the pin fits.
• ‒ Tighten injection pump sprocket securing bolts to
       25 Nm.

• ‒ Install toothed belt guard, vibration damper, belt pulley, and cylinder head cover.
• ‒ Install ribbed belt => Page 13-16 .