Diesel engine, 4 Cyl.
, Mechanics Page 1 of 9
Cylinder head removing and installing
Removing, installing and tensioning toothed belts
Special tools,
workshop
equipment, testers,
measuring
instruments and
auxiliary items
required
2068 A TDC
setting device
3359 Pin
T10098
Setting bar
10-222 A
Support device
with adapter
10-222 A/8
(Modifying
guide 10-222
A/21 => Page
15-9)
V/159 pin
wrench Matra
V.A.G 1331
Torque wrench
(5...50 Nm)
Special tools, workshop equipment,
testers, measuring instruments and
auxiliary items required
3036 Counter-hold
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 2 of 9
T40001 Two arm puller
Modifying guide 10-222 A/21 from
support device 10-222 A
Support device 10-222A is required to
support engine/gear box assembly.
A new hole is required on guide 10-222
A/21 to secure adapter 10-222 A/8 on it.
Dimensions given are in mm.
Drill a 12.5 mm (arrow) in guide
10-222 A/21.
Removing
Remove upper connecting pipe =>
Page 21-7.
Remove fuel filter with bracket.
Remove toothed belt guard upper
part.
Remove vacuum pump for brake
servo.
Remove ribbed belt => Page 13-13.
Engine installed:
Turn crankshaft to TDC No.1
cylinder -Arrow- (vehicles with
manual gearbox).
Note:
Use positioning handle for fall -3098- to turn
the engine by hand and place it at the
P.A.S. vane pump.
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 3 of 9
Turn crankshaft to TDC No.1
cylinder -Arrow- (vehicles with
automatic gearbox).
Note:
Use positioning handle for fall -3098- to turn
the engine by hand and place it at the
P.A.S. vane pump.
Engine removed:
Vehicles with manual gearbox
Install adjustment device 2068 A
as shown.
Set adjustment device to 96 mm -
arrow A-. The left-hand notch of the
vernier scale is reference point.
Turn crankshaft until flywheel TDC
marking aligns with the point of
setting device -arrow B-.
Vehicles with automatic Gearbox
Install adjustment device 2068 A
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 4 of 9
as shown.
Set adjustment device to 30 mm -
arrow A-. The left-hand notch of the
vernier scale is the reference point.
Turn crankshaft until the TDC
marking on drive plate aligns with
point of setting device -arrow B-.
Continued for all vehicles
Screw bolts -1- into cylinder head
onto stop by hand.
Lock camshaft with setting bar
T10098 as shown.
Lock injection pump sprocket with
pin 3359.
Loosen securing bolts-1- of injection
pump sprocket.
Notes:
Loosen securing bolts with free
thread shaft and point and renew.
(Spare part number of injection
pump sprocket 038 130 111 A).
Do not replace securing bolts without
free thread shaft and point. (Spare
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 5 of 9
part number of injection pump sprocket
038 130 111 B).
On no account must the nut -2-
for the hub be loosened. Otherwise
the injection pump basic setting will
be altered and this cannot be reset
with normal workshop equipment.
Loosen tensioner.
Fit support device 10-222 A with
legs 10-222 A/8 as illustrated.
Remove engine mounting-1- as
follows:
Remove bolts -arrows-.
Loosen bolt -arrow A-.
Notes:
Only remove engine mounting when
the engine is secured with the
support bracket 10-222A.
The engine bracket must be only
released when the engine mounting
is removed.
Remove engine mounting on cylinder
block.
Note:
When loosening the front engine mounting
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 6 of 9
bolt the engine must be raised slightly with
the support bracket.
Remove vibration damper/belt pulley.
Remove toothed belt guard centre
and lower parts.
Mark D.O.R. of toothed belt.
Take off toothed belt.
Installing
Check that TDC mark on flywheel
and the reference mark align.
Loosen camshaft sprocket securing
bolt 1 turn. To loosen the securing
bolt counter-hold camshaft sprocket
with counter hold 3036
Note:
Do never use the bar T10098 as counter
hold when loosening and tightening the
camshaft sprocket! Use the counter hold
3036.
Fit two arm puller T40001 on
centrally on camshaft sprocket with
single leg hook -A- and the double
leg hook -B- and pull off sprocket.
Counter-hold the puller with an open
jaw spanner -C- when doing this.
Fit toothed belts on crankshaft
toothed belt sprocket, idler wheel,
injection pump sprocket, coolant
pump sprocket and tensioning roller
(note direction of rotation).
Align injection pump sprocket to
centre position in elongated holes.
Fit camshaft sprocket together with
toothed belt and locate with securing
bolt (camshaft sprocket can still
turn).
Tension toothed belt. Using pin
wrench (e.g. Matra V159) on
eccentric turn clockwise until the
notch and the raised mark -arrows-
align.
Note:
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 7 of 9
Release tensioning roller completely and
tension again if eccentric has been turned
one time too far. Do not turn the eccentric
again only by the dimension which was too
far.
Tighten lock nut on tensioning roller.
Tightening torque: 20 Nm
Note:
Ensure that tensioning roller seats
correctly in rear toothed belt guard -arrow-.
Check TDC mark on flywheel again.
Tighten camshaft sprocket securing
bolt to 45 Nm (counter hold camshaft
sprocket with 3036).
Version -A-: Securing bolts with free
thread shaft and point -arrows-
Tighten new injection pump sprocket
securing bolts.
Tightening torque: 20 Nm
Notes:
After dynamically checking the
injection timing the bolts must be
tightened a further1/4 turn90
The securing bolts must only be
used once as these are stretch bolts.
Version -B-: Securing bolts without
free thread shaft and point
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 8 of 9
Tighten new injection pump sprocket
securing bolts.
Tightening torque: 25 Nm
Note:
Do not renew securing bolts.
Continued for all versions
Remove the setting bar T10098 from
camshaft.
Remove pin.
Turn crankshaft over two turns in
engine direction of rotation and
position again at TDC No. 1 cylinder.
Check if
the TDC marking on flywheel
the setting bar onto camshaft
the locking pin in injection pump
sprocket
the tensioning roller adjustment
(notch/raised portion)
or (notch/arrow)
fits.
If the notch and raised portion are
not aligned, tension tensioning roller
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.
Fit engine mounting to cylinder block.
Tightening torque 45 Nm
Note:
Tighten all bolts of the engine bracket, with
the tightening torque instructed, before
installing the engine mounting.
Engine mounting (renew securing
bolts).
Tightening torque: 40 Nm + 90
(1/4 turn)
Align engine mounting engine side
=> Page 10-15.
Tighten engine mounting to engine
bracket. When doing this put the
contact surfaces on the workbench
using the support device
10-222 A.
Tightening torque: 100 Nm
Install engine/body mounting.
Tightening torque: 25 Nm
Install vacuum pump.
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
Diesel engine, 4 Cyl., Mechanics Page 9 of 9
Install centre and lower toothed belt
guard and vibration damper/belt
pulley.
Install ribbed belt => Page 13-13.
Install fuel filter.
Install upper connecting pipe =>
Page 21-7.
Dynamically check the beginning of
injection:
=> Repair group 23; Servicing Diesel direct
injection system; Dynamically checking and
adjusting injection pump commencement of
delivery.
Install toothed belt guard - upper
part.
vw-wi://rl/V.en-GB.9C-MM-MMALH.wi::615691.xml?xsl=2 9/4/2015
