Removing, installing and tensioning injection pump toothed belt (engine codes AAB, AJA) — VW

ACV AHY AJA AJT AUF AXG AXL AYC
Special tools, workshop equipment, test and measuring appliances and auxiliary items required

2064 Pin
2066 Adapter for dial gauge
2068 A TDC setting device
3036 Retainer
VW 210 Checking appliance for V-belt and toothed belt

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

V.A.G 1331 Torque wrench (5 - 50 Nm)
V.A.G 1332 Torque wrench (40 - 200 Nm)
Dial gauge (measuring range 0...3 mm)

Removing

Remove insulation tray:

=> General body repairs; Repair group 50; Removing insulation tray
General body repairs
Removing insulation tray

Vehicles 09.94▸

Remove radiator grille:

=> General body repairs; Repair group 66; Servicing radiator grille
General body repairs
Servicing radiator grille

Continued for all vehicles

Remove left and right-hand securing bolts -1-.

Note:

Vehicles 09.94▸there is 1 securing bolt on each left and right-hand side of lock carrier.

Fold lock carrier with radiator out forwards -arrow-.

Remove injection pump toothed belt guard.
Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder:

Engine installed

Marks -arrows- on injection pump sprocket/console -C- and on flywheel/clutch bell housing -A- or drive plate/clutch bell housing -B-must align.

Engine removed

Set TDC setting device 2068 A to 82 mm -arrow A-, the left scale mark is the reference point.
Fit setting device as shown. Turn crankshaft until TDC mark on flywheel/drive plate aligns with edge of setting device -arrow B- and marks on injection pump sprocket and console also align.

Note:

This condition only occurs every 2nd TDC position.

Lock injection pump sprocket with pin 2064.
Mark D.O.R. of toothed belt.
Hold injection pump drive sprocket with counter-hold 3036. Remove securing bolt and take off drive sprocket with toothed belt.

Installing, tensioning

Check whether TDC mark on flywheel and reference mark are aligned.

Install injection pump drive toothed belt with injection pump drive sprocket. Tighten securing bolt until the drive sprocket can still just be turned by hand. For used toothed belts note direction of rotation.
Check toothed belt tension with test unit VW 210.
Scale value: 12...13

If scale value is not achieved:

Adjust toothed belt tension to scale value after loosening securing bolts -arrows- and moving console (with injection pump).

If scale value is achieved:

Remove pin 2064 from injection pump sprocket.

Install adapter for gauge 2066 and gauge (measuring range 0...3 mm) with 2.0 mm preload in place of sealing plug.
Check that crankshaft is still on TDC No. 1 cylinder and adjust commencement of injection as follows:

Notes:

The vehicle must be raised and readings made from below to enable the gauge to read whilst turning injection pump drive sprocket.
A second mechanic is required to observe the flywheel/clutch bell housing markings when checking the commencement of injection whilst turning crankshaft back and forth.

Turn injection pump drive sprocket against engine direction of rotation -direction of arrow A- using counter-hold 3036 until the gauge needle does not move any more.
Set gauge to "0".
Turn injection pump drive sprocket in engine direction of rotation -direction of arrow B- using counter-hold 3036 until the gauge reads:
Engine code AAB
1.00 ±0.02 mm lift (commencement of injection).
Engine code AJA
0.90 ±0.02 mm lift (commencement of injection).
Hold injection pump drive sprocket in this position with counter-hold 3036 and pre-tighten to
50 Nm.

Note:

The commencement of injection must be checked again by turning crankshaft back via vibration damper to gauge reading "0" and forward to TDC. The value will deviate due to toothed belt step.

The commencement of injection is to be reset a second time taking deviation into account.

Example:

/ - · First value / Checked value · 1.00 / 0.93 · mm / mm
= · Deviation · 0.07 · mm
Value for second adjustment · 1.07 · mm

Hold injection pump drive sprocket, after second adjustment with counter-hold 3036 and tighten to
100 Nm.
Install toothed belt guard for injection pump.
Install radiator with lock carrier.
Install insulation tray.