VIDEO PART 2 - Install new Injection toothed belt with new tensioner and new idler roller and set injection pump on VW T4 ACV 2.5TDI 75KW
Patrik Kőlbl -
Prerequisites
Marks -arrows- on injection pump pulley/bracket -C- and flywheel/ clutch housing -A- or drive plate/clutch housing -B- must align (This condition is only achieved every 2nd TDC - top dead center - position.)
Job
Check whether TDC mark on flywheel and reference mark are aligned.
Fit toothed belt onto injection pump pulley.
Fit injection pump drive pulley into toothed belt and secure gear on camshaft so that the gear can still turn.
Install idler roller
Install idler roller -1-.
Turn idler roller so that indicator aligns with flange contour of cylinder head -arrow-.
Tighten securing nut -2- to 20 Nm.
idler roller
Install belt tensioner
Install belt tensioner -1- so that belt tensioner tab seats in cutout on bracket -arrow B-.
Tighten securing bolt hand-tight.
To tension toothed belt, turn belt tensioner anti-clockwise until both indicators are aligned -arrow A.
Tighten securing bolt to 15 Nm.
Tighten injection pump drive pulley securing nut to 160 Nm.
Use counterhold tool -3036- for this.
belt tensioner
Loosen locking bolt -2- on injection pump.
Insert intermediate plate -1- and tighten locking bolt to 12 Nm.
Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
Check
The marking on the injection pump pulley must align with the marking on the injection pump -arrows-. If injection pump pulley marking is not visible, turn crankshaft one turn further.
Check position of indicators -arrow A- on the belt tensioner. The indicators must align. If the indicators do not align, but the front indicator is located within the underlying sheet metal contour, this is permissible.
Fine tune injection pump timing with clock
Screw in the injection pump adapter 3313 instead of plug.
Insert dial gauge (clock) (measuring range 0...3.0 mm) into adapter with pre-tension of approx. 2.0 mm.
Check that mark on injection pump pulley and injection pump are aligned (picture above v23-0324).
Loosen locking bolt -2- on injection pump
Remove underlying intermediate plate -1-.
Set dial gauge to “0”.
To ensure the injection pump high-pressure pistons are at BDC, turn injection pump pulley slowly counter to engine direction of rotation (clockwise) using counterhold tool -3036- . The dial gauge indicator must remain at “0”, reset dial gauge to “0” after reaching BDC if necessary
Turn injection pump pulley slowly in engine direction of rotation (anti-clockwise) until dial gauge indicator shows 0.55 mm stroke using counterhold tool -3036- .