Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 10-222A Engine support bracket with legs 10-222A/1
• ◆ 2064 Mandrel (for single-part injection pump sprocket)
• ◆ 2065 A Setting bar
• ◆ 2068 A Adjustment bar (for TDC of removed engine)
• ◆ 3036 Counter hold tool
• ◆ 3359 Mandrel for diesel injection pump (for two-part injection pump sprocket)

• ◆ 3387 Pin wrench
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1590 Coolant pump wrench
• ◆ Drift
• ◆ Feeler gauges

Belt drive with single part injection pump sprocket

Belt drive with two-part injection pump sprocket

Removing

• ‒ → Fit engine support bracket 10-222A with legs 10-222A/1.
• ‒ Locate support bracket in lifting eye on cylinder head and take-up weight of engine.
• ‒ Remove connecting hose for air cleaner/air intake connecting piece.
• ‒ Remove ribbed belt .
• ‒ Disconnect pendulum support at mounting.

• ‒ Remove upper toothed belt guard and cylinder head cover.
• ‒ → Remove bolts from engine mounting -arrows- and remove mounting complete.
• ‒ Remove engine mounting on cylinder block.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow-.

Engine removed:

• ‒ → Bolt on adjustment bar 2068 A as shown.
• ‒ Set bar to 13.0 mm. The left notch on the vernier scale -arrow A- is the reference point.
• ‒ Turn crankshaft until the flywheel TDC mark the point of the unit -arrow b- are aligned.

• ‒ → Lock camshaft with setting bar 2065 A.
• ‒ 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 mandrel 2064.
• ‒ Loosen tensioner.
• ‒ Carefully lower engine slightly.
• ‒ Remove coolant pump pulley (use water pump wrench V.A.G 1590 to loosen and tighten the securing bolt).
• ‒ Remove vibration damper and belt pulley.
• ‒ Remove ribbed belt tensioning roller.
• ‒ Remove lower toothed belt guard.
• ‒ Mark D.O.R. of toothed belt.
• ‒ Remove idler wheel.
• ‒ Take off toothed belt.

Installing

• ‒ Check whether TDC mark on flywheel and reference mark are aligned.
• ‒ → Loosen camshaft sprocket securing bolt one half turn, holding camshaft sprocket with counter-hold tool 3036.

Note:

Never use setting bar 2065 A as a counter hold when loosening and tightening the camshaft sprocket! Use counter-hold tool3036.

• ‒ → Loosen camshaft sprocket from camshaft taper by tapping with hammer (using a drift through rear toothed belt guard opening).
• ‒ 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 3387 to right until notch aligns with raised portion -arrows-.

Note:

If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must never be turned back when it has been turned too far.

• ‒ 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 2065 A from camshaft and mandrel 2064 from injection pump sprocket.
• ‒ Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.

• ‒ Check if
       the TDC mark on flywheel
       the setting bar on camshaft
       the mandrel 2064 in injection pump sprocket
       the tensioning roller setting (notch/raised mark)
  align/are fitted correctly.
• ‒ If notch and raised mark do not align, tension the tensioning roller. To do this, hold tensioning roller with pin wrench 3387, loosen securing nut, turn eccentric clockwise further until notch and raised mark align opposite one another and tighten securing nut to 20 Nm.
• ‒ Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
• ‒ Repeat check.
• ‒ Install toothed belt guard, vibration damper (note fixing), V-belt pulley tensioning roller, coolant belt pulley and cylinder head cover.
• ‒ Fit engine mounting to cylinder block.
       Tightening torque: 45 Nm
• ‒ Install engine assembly mounting.
  Tightening torque => Page 10-11 .
• ‒ Install ribbed belt => Page 13-13 .
• ‒ Install noise insulation tray.
• ‒ Install connecting hose for air cleaner/air intake connecting piece.
• ‒ Install pendulum support free of tension.
  Tightening torque assembly mountings
  => Page 10-11 .
• ‒ Checking injection pump commencement of delivery:

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

Belt drive with two part injection pump sprocket

Removing

• ‒ → Fit engine support bracket 10-222A with legs 10-222A/1.
• ‒ Locate support bracket in lifting eye on cylinder head and take-up weight of engine.
• ‒ Remove connecting hose for air cleaner/air intake connecting piece.
• ‒ Remove ribbed belt => Page 13-13 .
• ‒ Disconnect pendulum support at mounting.
• ‒ Remove upper toothed belt guard and cylinder head cover.

• ‒ → Remove bolts from engine mounting -arrows- and remove mounting complete.
• ‒ Remove engine mounting on cylinder block.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow-.

Engine removed:

• ‒ → Bolt on adjustment bar 2068 A as shown.
• ‒ Set bar to 13.0 mm. The left notch on the vernier scale -arrow A- is the reference point.
• ‒ Turn crankshaft until the flywheel TDC mark the point of the unit -arrow b- are aligned.

• ‒ → Lock camshaft with setting bar 2065 A.
• ‒ 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.
• ‒ Carefully lower engine slightly.
• ‒ Remove coolant pump pulley (use water pump wrench V.A.G 1590 to loosen and tighten the securing bolt).
• ‒ Remove vibration damper/belt pulley.
• ‒ Remove ribbed belt tensioning roller.
• ‒ 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 one half turn, holding camshaft sprocket with counter-hold tool 3036.

Note:

Never use setting bar 2065 A as a counter hold when loosening and tightening the camshaft sprocket! Use counter-hold tool3036.

• ‒ → Loosen camshaft sprocket from camshaft taper by tapping with 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 3387 to right until notch aligns with raised portion -arrows-.

Note:

If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must never be turned back when it has been turned too far.

• ‒ 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 2065 A from camshaft and pin 3359 from injection pump sprocket.
• ‒ Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
• ‒ Check if
       the TDC marking on flywheel
       the setting bar on camshaft
       the pin 3359 in injection pump sprocket
       the tensioning roller setting (notch/raised mark)
  align/are fitted correctly.
• ‒ If notch and raised mark do not align, tension the tensioning roller. To do this, hold tensioning roller with pin wrench 3387, loosen securing nut, turn eccentric clockwise further until notch and raised mark align opposite one another and tighten securing nut to 20 Nm.

→ If the injection pump sprocket cannot be locked with pin 3359:

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

• ‒ Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
• ‒ Repeat check.
• ‒ Install toothed belt guard, vibration damper (note fixing), V-belt pulley tensioning roller, coolant belt pulley and cylinder head cover.
• ‒ Fit engine mounting to cylinder block.
       Tightening torque: 45 Nm
• ‒ Install engine assembly mounting.
  Tightening torque => Page 10-11 .
• ‒ Install ribbed belt => Page 13-13 .
• ‒ Install noise insulation tray.
• ‒ Install connecting hose for air cleaner/air intake connecting piece.
• ‒ Install pendulum support free of tension.
  Tightening torque assembly mountings
  => Page 10-11 .
• ‒ Check injection pump commencement of delivery:

=> Repair group 23; Servicing fuel injection system; Checking commencement of injection and adjusting if necessary