Volkswagen Workshop Service and Repair Manuals

Special tools, testers, measuring instruments and auxiliary items required

• ◆ Setting bar 2065 A
• ◆ Pin 2064
• ◆ Torque wrench V.A.G 1331 (5...50 Nm)

• ‒ Remove upper toothed belt guard and cylinder head cover.
• ‒ Check tension of toothed belt.
• ‒ → Set engine to TDC No. 1 cylinder -arrow-. Setting bar must fit into the camshaft slot. If it is not possible to insert the bar, adjust valve timing as follows.
• ‒ Rotate camshaft so that setting bar can be inserted.
• ‒ 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.
• ‒ 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).

• ‒ → Lock injection pump sprocket with pin 2064.
• ‒ Check TDC, if necessary turn crankshaft until TDC mark on flywheel aligns with mark on bell housing => Fig. 23-169, Page 23-28
  
• ‒ Remove pin.
• ‒ Tighten camshaft sprocket securing bolt to 45 Nm.
• ‒ Remove setting bar.
• ‒ Dynamically check commencement of injection
  =>Page 23-24