Removing, installing and tensioning injection pump toothed belt (engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC, AYY) — VW

Removing, installing and tensioning injection pump toothed belt (engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC, AYY)
Special tools and workshop equipment required
TDC setting device
2068 A
Counterhold tool
3036
Adapter
3313
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Dial gauge (measuring range 0…0.3 mm)
Removing
Remove noise insulation tray
Rep. Gr.
50
.
Remove radiator grille
Rep. Gr.
66
Engine codes ACV, AUF, AYC
Remove bracket for charge air cooler
1
Continuation for all vehicles
Remove securing bolts
2
on left and right
Fold lock carrier with radiator out forwards
arrow
Engine codes AHY, AXG, AXL
Remove charge air cooler/intake manifold connecting pipe
Loosen securing bolt for coolant pipe on starter
Continuation for all vehicles
Remove injection pump toothed belt guard
Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder:
Engine installed
Engine codes ACV, AJT, AUF, AYC, AYY
Marks
arrows
on injection pump pulley/bracket
C
and flywheel/clutch housing
A
or drive plate/clutch housing
B
must align.
Engine codes ACV-Syncro, AHY, AXG, AXL
Marks
arrows
on injection pump pulley/bracket
C
and flywheel/clutch housing
A
or drive plate/clutch housing
B
must align.
Note
This condition is only achieved every 2nd TDC position.
Engine removed
Set
TDC adjustment bar
2068 A
to 82 mm
arrow A
, left notch of vernier scale is reference point
Screw in
TDC adjustment bar
2068 A
as shown; turn crankshaft until TDC mark on flywheel/drive plate aligns with edge of
TDC adjustment bar
2068 A
arrow
and marks on injection pump pulley and bracket align
Note
This condition is only achieved every 2nd TDC position.
Mark direction of rotation of toothed belt
Hold injection pump drive pulley with
counterhold tool
3036
; unscrew securing bolt and remove toothed belt
Remove toothed belt tensioner
Installing, tensioning
Screw in
adapter
3313
instead of plug.
Insert dial gauge (measuring range 0...3.0 mm) into adapter with pre-tension of approx. 2.0 mm.
Check that mark on injection pump pulley and injection pump are aligned
arrows
.
Loosen locking bolt
2
on injection pump.
Remove underlying intermediate plate
1
.
Set dial gauge to
“0”
.
To ensure the injection pump high-pressure pistons are at BDC, turn injection pump pulley slowly counter to engine direction of rotation (clockwise) using
counterhold tool
3036
. The dial gauge indicator must remain at
“0”
, reset dial gauge to
“0”
after reaching BDC if necessary.
Turn injection pump pulley slowly in engine direction of rotation (anti-clockwise) until dial gauge indicator shows 0.55 mm stroke using
counterhold tool
3036
.
Tighten locking bolt to 30 Nm.
Check whether TDC mark on flywheel and reference mark are aligned.
Fit toothed belt onto injection pump pulley.
Note direction of rotation with used belts.
Fit injection pump drive pulley into toothed belt and secure gear on camshaft so that the gear can still turn.
Check installation position of idler roller:
Turn idler roller so that indicator aligns with flange contour of cylinder head
arrow
.
Tighten securing nut
2
to 20 Nm.
Install belt tensioner
1
so that belt tensioner tab seats in cut-out on bracket
arrow B
.
Tighten securing bolt hand-tight.
To tension toothed belt, turn belt tensioner anti-clockwise until both indicators are aligned -arrow A.
Tighten securing bolt to 15 Nm.
Tighten injection pump drive pulley securing nut to 160 Nm. Use
counterhold tool
3036
for this.
Note
When tightening the securing bolt, ensure that no torque is transmitted to the injection pump shaft, which is locked at commencement of injection.
Loosen locking bolt
2
on injection pump.
Insert intermediate plate
1
and tighten locking bolt to 12 Nm.
Remove dial gauge and screw plug into injection pump.
Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
Check position of indicators
arrow A
. The indicators must align. If the indicators do not align, but the front indicator is located within the underlying sheet metal contour, this is permissible.
Note
If the front indicator lies outside of the underlying sheet metal contour, the tensioning process must be repeated.
Install toothed belt guard.
Engine codes AHY, AXG, AXL
Install charge air cooler/intake manifold connecting pipe
Tighten securing bolt for coolant pipe on starter
Continuation for all vehicles
Dynamically checking commencement of injection and adjusting if necessary
Rep. Gr.
23
Install radiator with lock carrier
Install noise insulation tray
Rep. Gr.
50
.