Removal and Replacement

Toothed belts, removing, installing, tensioning

Special tools and equipment
^ 2068 A Adj. gauge TDC tool
^ 3359 Rig pin
^ 3418 Adjustment guide
^ 10-222A Engine support bridge with 10-222A/1 bracket for engine
^ V/159 nut wrench
^ VAG 1331 Torque wrench: 5 to 50 Nm (3.7 to 37 ft. lbs.)

Support tool 10-222 A/21, modifications

Note:
^ Use tool 10-222A to support the engine / transmission assembly.

^ Drill a new hole in the 10-222 A/21 guide to fasten 10-222 A/8 adaptor to.
^ Dimensions given are in mm.
^ One hole 12.5 mm diameter (arrow) drilled in the 10-222 A/21 guide

Toothed belts, removing
- Remove tube between charge air cooler and Air intake pipe
- Disconnect fuel supply and return lines at fuel filter.
- Remove fuel filter from bracket.
- Remove toothed belt guard - upper section.
- Remove valve cover.

Note: The valve cover has an integrated, vulcanized gasket. If damaged or leaking replace the valve cover.

- Remove brake booster vacuum pump.
- Remove pipe between charge air cooler and turbocharger.
- Remove insulation tray - right side
- Remove ribbed belt.

With engine installed:

- Turn crankshaft to cylinder 1 TDC.

With engine removed:

- Turn crankshaft to cylinder 1 TDC.

Vehicles with manual transmission

- Install adjustment device 2068 A as shown.
- Set adjustment device to 96 mm (arrow -A-). Left-hand notch of vernier scale is reference point.
- Turn crankshaft until flywheel TDC marking aligns with point on setting device (arrow -B-).

Vehicles with automatic transmission

- Lock camshaft using setting bar.
- 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.
- Loosen injection pump sprocket mounting bolts -1-.

Note: Do NOT loosen hub nut -2-! Otherwise the Diesel injection pump basic setting will be altered and cannot be reset with normal workshop equipment.

- Loosen tensioner.

- Install 1 0-222A support with 1 0-222A/1 legs as shown.

- Remove engine mount -1- as follows:
- Unscrew bolts (arrows)

- Remove vibration damper/belt pulley.
- Remove toothed belt guard center and lower sections.
- Mark engine direction of rotation on the toothed belt.
- Remove toothed belt.

Toothed belts, installing
- Make sure that TDC mark on flywheel and reference mark are aligned.
- Loosen camshaft sprocket mounting bolt 1/2 turn.

- Place a drift through hole in rear of toothed belt guard and release the camshaft sprocket from camshaft taper with a light and careful hammer blow.
- Install toothed belts (note engine direction of rotation) on crankshaft toothed belt sprocket, intermediate wheel, injection pump sprocket and tensioning roller.
- Install camshaft sprocket together with toothed belt and position using mounting bolt.
^ Camshaft sprocket should still turn

- Tension toothed belt; using pin wrench on eccentric, turn clockwise until notch and raised mark align (arrows).
- Tighten lock nut on tensioning roller.
^ Tightening torque: 20 Nm (15 ft. lbs.)

Note: Observe correct installation of tension roller in rear toothed belt guard (arrow).

- Check TDC mark on flywheel again.
- Tighten camshaft sprocket mounting bolt.
^ 45 Nm (33 ft. lbs.)
- Tighten the new mounting bolts of injection pump sprocket
^ Tightening torque: 20 Nm (15 ft. lbs.)

Note: After dynamically checking the "start of injection", the mounting bolts must be retightened 90° (1/4 turn).

- The mounting bolts should only be used one time, since by design they have a reduced shank

- Remove 2065A setting bar from camshaft.
- Remove pin.
- Turn crankshaft two rotations in engine direction of rotation and set again to cylinder 1 TDC.
- Attach bracket to engine block.
- Install engine mount (replace mounting bolts).
^ Tightening torque: 40 Nm (30 ft. lbs.) plus additional 90°(1/4 turn)
- Securely install mount for engine to engine bracket (replace mounting bolts)
^ Tightening torque: 60 Nm (44 ft. lbs.) plus additional 90°(1/4 turn)
- Install bracket for subassembly/body
^ Tightening torque: 25 Nm (18 ft. lbs.)
- Install vacuum pump.
- Install toothed belt guard, vibration damper belt pulley, and valve cover.
- Install ribbed belt.
- Install sound dampening tray and engine cover
- Remove pipe between charge air cooler and turbocharger.
- Install fuel filter with bracket
- Disconnect fuel supply and return lines at fuel filter.
- Install pipe between charge air cooler and intake pipe.
- Check Diesel injection pump "start of delivery"