Procedures
Special Tools. workshop equipment, test and measuring appliances and aux. items required
2068 A TDC tool
3359 Pin
3418 Setting tool
10-222A Engine support bracket with 10-222N1 legs
V159 Nut wrench
VAG1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb)
Support tool 10-222 A/21, modifications
Notes:
Use tool 10-222A to support the engine / transmission assembly.
Drill a new hole in the 10-222 A/27 guide to fasten 70-222 A/B adaptor to.
Dimensions given are in mm.
One hole 12.5 mm (arrow) drilled in the 10-222 A/21 guide
Toothed Belts, removing
- Remove tube between charge air cooler and Air intake pipe. Refer to: "Powertrain Management : Turbocharger : Service and Repair" Service and Repair
- Disconnect fuel supply and return lines at fuel filter.
- Remove fuel filter from bracket.
- Remove toothed belt guard - upper section.
- Remove valve cover.
- Remove brake booster vacuum pump.
- Remove pipe between charge air cooler and turbocharger. Refer to: "Powertrain Management : Turbocharger : Service and Repair" Service and Repair
- Remove insulation tray - right side
- Remove ribbed belt. Refer to: "Engine : Drive Belt : Service and Repair" Service and Repair
With Engine Installed:
- Turn crankshaft to cylinder 1 TDC.
- Turn crankshaft to cylinder 1 TDC.
With Engine Removed:
Vehicles with Manual Transmission
- Install adjustment device 2068A as shown.
- Set adjustment device to 96 mm -arrow A-. The left-hand notch of the vernier scale is the reference point.
- Turn crankshaft until flywheel TDC marking aligns with point on setting device -arrow B-.
Vehicles with Automatic Transmission
- Install adjustment device 2068A 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 point of setting device -arrow B-.
All Vehicles
- 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 halt 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 10-222A support with 10-222A/1 legs as shown.
- Remove engine mount -1-as follows:
- Unscrew bolts -arrows-
- Remove vibration damper/belt pulley.
- Install toothed belt guard center and lower sections.
- Mark engine direction of rotation on the toothed belt.
- Remove toothed belt.
Toothed Belts, installing
- Ensure 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 lb)
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 lb)
- Tighten the new mounting bolts of injection pump sprocket
- Tightening torque: 20 Nm (15 ft lb)
Notes:
- After dynamically testing the "start of injection" re-tighten the mounting bolts about 90° (1/4 turn.). Refer to: "Powertrain Management : Diesel MFI Pump : Service and Repair" Service and Repair
- 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 engine direction of rotation and set again to cylinder 1 TDC.
- Attach bracket to cylinder block.
- Install engine mount (replace mounting bolts).
- Tightening torque: 40 Nm (30 ft lb) + 90°(1/4 turn)
- Securely install mount for engine to engine bracket (replace mounting bolts)
- Tightening torque: 60 Nm (44 ft lb) + 90°(1/4 turn)
- Install bracket for subassembly/body
- Tightening torque: 25 Nm (18 ft lb)
- Install vacuum pump.
- Install toothed bell guard, vibration damper, belt pulley, and valve cover.
- Install ribbed belt. Refer to: "Engine : Drive Belt : Service and Repair" Service and Repair
- Install sound dampening tray and engine cover.
- Remove pipe between charge air cooler and turbocharger. Refer to: "Powertrain Management : Turbocharger : Service and Repair" Service and Repair
- Install fuel filter with bracket
- Disconnect fuel supply and return lines at fuel filter.
- Install pipe between charge air cooler and intake pipe. Refer to: "Powertrain Management : Turbocharger : Service and Repair" Service and Repair
- Check Diesel injection pump. Refer to: "Powertrain Management : Diesel MFI Pump : Service and Repair" Service and Repair