Two sets of probes are used, a VW 2065 or 2065 A adjusting ruler and a 2064 mandrel. The mandrel and ruler can be made according to the attached drawings (see fig.).
This is how the mandrel for the timing belt pulley of the fuel pump looks like. This is a simple round blank; a handle at the rear end is optional. The length is also unimportant. Decisive factor: The mandrel must be positioned between the hole in the fuel pump pulley and the hole in the pump bracket. It is important that the mandrel has a certain diameter. It should be exactly equal to 15.45 mm. | According to these dimensions, you can make an installation ruler. The exact length is not that important. The shim must be at least as long as the side of the cylinder head indicated. |
Remove the valve cover and timing belt cover.
Set the first cylinder to top dead center (TDC).
Insert the setting ruler into the transverse slot of the shaft at the end of the camshaft, directed to the left in motion.
Now, between the cylinder head and the setting ruler, at both ends of the ruler, insert one sheet of the probe of the same thickness; thickness must be set! See drawing. This eliminates the play between the setting ruler and the cylinder head - the camshaft can no longer be rotated.
Stop the fuel pump. To do this, insert mandrel 2064 into the small hole in the impeller (hole pointing to the right) and into the hole located behind the pump holder.
Loosen the toothed belt tensioner nut.
Turn the tension roller to the left; this loosens the tension of the toothed belt.
Remove V-belt.
Remove the V-belt pulley and cover.
Remove toothed belt
Before installing a new timing belt, loosen the camshaft timing belt pulley fixing screw 1/2 turn.
Remove the camshaft pulley with a light blow from a rubber mallet from the camshaft cone.
Now the pulley can turn on the camshaft.
Check again if the crankshaft is at top dead center (TDC); that the camshaft and fuel pump are correctly fixed.
Install toothed belt and tighten it (see previous section) Do not rotate the crankshaft while doing this.
Tighten the fixing screw of the toothed belt pulley with a tightening torque of 45 Nm.
Tighten the toothed belt again. The crankshaft can now be turned.
Be sure to check the start of the fuel pump.
Install covers.
Install the V-belt and tension it. See section "Checking the tension of the V-belt", chapter "Generator".
Fixing the TDC position at the camshaft using the adjusting ruler (2): to equalize the backlash between the cylinder head and the ruler, feeler gauge sheets of the same thickness are placed at both ends of the ruler (1 and 3) In the illustration on the right you can see the cross cut of the camshaft (arrow), in which to insert the adjustment ruler.
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