Warning: Operations and related instructions applicable to all engines are given in subsection Removal, installation and tension of a toothed belt. This subsection only describes the differences relating to the 1.9l TDI engine.
1. Turn away a tension roller of a V-belt at the holder.
2. Remove the brake booster vacuum pump.
3. Set the engine crankshaft to the TDC position of the piston of the first cylinder (subsection Setting the piston of the first cylinder to TDC). In this position, the adjusting ruler 3418 can be inserted into the slot of the camshaft. The ruler prevents the camshaft from turning. If necessary, the ruler can be made by yourself.
4. Installing the adjusting bar parallel to the cylinder head: To do this, turn the crankshaft so that the end of the ruler adjoins the cylinder head. At the other end of the ruler, measure the resulting gap with a feeler gauge. Insert a feeler gauge with a thickness equal to half that obtained between the ruler and the cylinder head. Now rotate the engine so that the ruler lies on the dipstick. Insert a second feeler gauge of the same size at the other end between the ruler and the cylinder head.
5. In the hole near the clutch housing, the flywheel TDC mark and the base mark are opposite each other.
6. Fix the injection pump pulley with the AUDI-3359 rod. Instead of the specified rod, another suitable one, for example, a drill, can be used. Loosen the mounting bolts one by one (arrows on the accompanying illustration) and replace with new bolts. Tighten the bolts to 20 Nm.
Warning: Do not loosen the central bolt on the injection pump, as this may interfere with pump regulation. Independent adjustment of the injection pump is difficult.
7. Tie up the engine and unscrew the right engine mount and vibration damper, refer to subsection Removal, installation and tension of a toothed belt.
8. Remove the toothed belt.
9. Loosen the camshaft gear bolt by ½ turn with the toothed belt removed.
Warning: When loosening the wheel, hold the flats of the camshaft with a wrench. Do not use the shim as a holding device.
10. Loosen the gear wheel. Remove the camshaft sprocket from the cone by hitting the drift with a hammer through the hole in the rear toothed belt guard.
11. Put on the toothed belt. When installing a used belt, keep the direction of rotation in mind. The arrow applied when removing the belt points in the direction of rotation of the engine, i.e. in the clockwise direction. Put on the belt in the sequence: crankshaft pulley, deflection roller, coolant pump, injection pump pulley and tensioner pulley.
12. Put the camshaft pulley together with the belt on the camshaft and secure by hand with a bolt. The camshaft pulley must still rotate on the shaft.
13. Remove the injection pump pulley retainer.
14. Turn the tensioning roller with a tool, eg HAZET 2587 to the right, so that the mark on the tensioning roller and the protrusion coincide.
15. Tighten the clamping nut on the tension roller to 20 Nm.
16. Check again if the TDC marking on the flywheel and the base marking match.
17. Secure the camshaft pulley with a torque of 45 Nm, while holding the shaft from turning with a wrench.
18. Remove the adjuster on the camshaft.
19. Remove the AUDI-3359 rod from the injection pump pulley.
20. Turn the crankshaft two turns and stop again at the TDC position of the first cylinder.
21. Check if the injection pump pulley is fixed with the AUDI-3359 rod. If the rod does not insert, remove the injection pump pulley bolts and turn the hub so that the rod enters.
22. Secure the engine mount to the cylinder block with a torque of 45 Nm.
23. Tighten the engine mounts.
Warning: Bolts undergo permanent deformation during the tightening process. Therefore, after each tightening, they must be replaced. Fasten the engine mount to the support with a torque of 60 Nm and then tighten with a hard wrench at an angle of 90° (1/4 turn). Fasten the engine mounts to the body with a torque of 40 Nm and then tighten with a hard wrench at an angle of 90° (1/4 turn).
24. Reinstall the toothed belt guard, vibration damper,. V-belt tensioner and cylinder head cover.
25. Install the V-belt, refer to subsection Removing and installing the V-belt.
26. Check start of injection pump (service station work).
Warning: After adjusting the start of fuel injection, it is necessary to tighten the bolts securing the injection pump pulley to a torque of 20 N·m and then tighten them with a hard wrench at an angle of 90° (1/4 turn). After tightening the bolts in the specified way, they must be replaced with new ones after each unscrewing.
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