- insert the edge of the retainer into the groove of the rear flange of the camshaft;
- turn the camshaft until one end of the retainer touches the surface of the cylinder head;
- measure the gap between the cylinder head surface and the other end of the retainer;
- place a shim under both ends of the retainer that is half the thickness of the measured gap between the cylinder head surface and the end of the retainer. The total thickness of the two shims should be equal to the measured gap.
Remove the upper front toothed belt cover, loosen the toothed belt tension and remove it from the camshaft and injection pump toothed pulleys. Loosen the injection pump drive toothed pulley fastening nut.
Install the puller on the toothed pulley of the fuel injection pump drive (Fig. 3-36). Press the pulley off the fuel injection pump drive shaft by hitting the pulley with a hammer with an aluminum striker. Remove the puller. Remove the pulley mounting nut, then remove the pulley. Disconnect the wires from the electromagnetic shut-off valve. Disconnect the fuel supply and starting device control cables from the fuel injection pump. On engines "RA", "SB", "AAZ" disconnect the vacuum hose from the boost pressure corrector. Disconnect the high-pressure fuel lines from the injectors and the high-pressure fuel pump. Plug the holes in the fuel lines and the high-pressure fuel pump. Loosen the bolts securing the high-pressure fuel pump to the bracket and remove the high-pressure fuel pump. To install, place the high-pressure fuel pump on the bracket, aligning the timing marks on the high-pressure fuel pump body and the rear protective cover of the toothed belt. Tighten the high-pressure fuel pump mounting bolts. Make sure that the key is in the groove of the high-pressure fuel pump drive shaft, install the high-pressure fuel pump drive toothed pulley, screw on the mounting nut and turn the pulley until the marks on the pulley and the high-pressure fuel pump body are aligned (Fig. 3-20). Lock the high-pressure fuel pump drive toothed pulley with the VW 20 64 lock (Fig. 3-37) and tighten the pulley mounting nut. Loosen the camshaft toothed pulley mounting bolt by half a turn and separate the pulley from the cone using blows from a hammer with a rubber striker (engines "1Y", "RA", "SB") or by striking a drift inserted into the hole in the rear protective cover of the toothed belt (engine "AAZ"). Make sure that the mark on the flywheel corresponding to the TDC of piston No.1 cylinder is precisely aligned with the mark on the clutch housing. Put the toothed belt on the pulleys, remove the retainer and adjust the toothed belt tension using the VW 210 tool, as indicated in the subsection "Removing and installing the camshaft drive belt". Tighten the camshaft toothed pulley mounting bolt to a torque of 4.5 kgf·m. Turn the crankshaft two turns and check the toothed belt tension again. Adjust the fuel injection advance angle as indicated below. Connect the fuel lines to the injectors and the high-pressure fuel pump.
Warning. The fittings for fastening the supply and drain fuel lines to the high-pressure fuel pump are the same size, but it is prohibited to swap them, since the fitting of the drain fuel line marked "OUT" (Fig. 3-38) has a ball check valve.
The original text can be found on the portal (vwmanual.ru)
Connect the solenoid stop valve connector.
Connect the fuel supply and starting device control cables to the high-pressure fuel pump. On engines "RA", "SB", "AAZ" connect the vacuum hose to the boost pressure corrector. Install the front timing belt cover. Remove the camshaft retainer. Install the cylinder head cover.
Connect the wire to the negative terminal of the battery.
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