Timing Marks, I5Diesel, 98 VW LT van

[Tonybolony]

Can anyone help?
My lad has stripped this unit, as tensioner wheel collapsed, and threw the belt. Head built back up, but he can't find his autodata book with timing/tensioning info.
Any help gratefully recieved- even just a link to a website that can be trusted for the info.
Thanks!

Ps The 'Head Set' he bought to refit the head, had no head gasket- and the lad in the motor factors says it's not supposed to! Not only that- they didn't have one in stock til tomorrow.
Is it Me????

[AndyP]

Engine code?

The AEL 'head sets' I looked at for mine were also minus the headgasket

[Tonybolony]

Thanks for the reply Andy- he's trying to find the engine code now, what I can tell you is it is the 10v single-cam turbo unit, poss AHD code??

[mdz]

AHD

[Tonybolony]

Many thanks MDZ, that is just what he was looking for

[Monkeymagic]

these things are easy once you do a couple. its pump timing that's tricky. if you get stuck pm me i do loads of them.
look on brick yard there is a write up on there.

[Monkeymagic]

ps diesel head sets usually consist of a de coke kit. you buy head gasket separate

[5cylinderman]

Timing an I5 Tdi

Firstly you need to set the crank, pump and camshaft at TDC before belt fitment.
The pump uses a locking pin between the belt pulley and the pump body (12mm?).
The rear end of the cam has a slot that usually needs a flat "special tool" but you can improvise with strip of flat steel if necessary.
The cam belt pulley is held on the tapered end of the cam with a bolt. Be careful when releasing the pulley from the taper, just use sharp taps instead of brute force. It is possible to distort the pulley with abuse.
Do not trust the TDC mark on the front pulley (small dot). Use the correct mark through the window into the flywheel and make sure you are looking at the correct mark. These diesels are fussy on correct timing. There is one particularly stubborn bolt holding the pump to its mounting bracket on these motors. It lives behind the pump "nearest the camshaft". Do not over tighten this fella, just give it a "nip". I'm away from home for a while but I'm sure there are others that can post images of the marks and belt tension settings.
Once all set up check it all again and again. Once up and running you will need to check your pump timing with VCDS (Vag Com). Using a dial gauge in the rear of the pump is a waste of time IMHO, BTDT.

[Tonybolony]

these things are easy once you do a couple. its pump timing that's tricky. if you get stuck pm me i do loads of them.
look on brick yard there is a write up on there.

Cheers Monkey, I may just take you up on that.
I've said it before, and I'll say it again- the level of comaraderie (I think I've spelt that correctly) on this forum never ceases to amaze me.

[Tonybolony]

Firstly you need to set the crank, pump and camshaft at TDC before belt fitment.
The pump uses a locking pin between the belt pulley and the pump body (12mm?).
The rear end of the cam has a slot that usually needs a flat "special tool" but you can improvise with strip of flat steel if necessary.
The cam belt pulley is held on the tapered end of the cam with a bolt. Be careful when releasing the pulley from the taper, just use sharp taps instead of brute force. It is possible to distort the pulley with abuse.
Do not trust the TDC mark on the front pulley (small dot). Use the correct mark through the window into the flywheel and make sure you are looking at the correct mark. These diesels are fussy on correct timing. There is one particularly stubborn bolt holding the pump to its mounting bracket on these motors. It lives behind the pump "nearest the camshaft". Do not over tighten this fella, just give it a "nip". I'm away from home for a while but I'm sure there are others that can post images of the marks and belt tension settings.
Once all set up check it all again and again. Once up and running you will need to check your pump timing with VCDS (Vag Com). Using a dial gauge in the rear of the pump is a waste of time IMHO, BTDT.

Regarding the 'pump locking pin', does that fit in hole behind bolt/bracket 18/19 in drawing above??

[Christophski]

Locking pin is number 18. It's just a bolt you do up once timing is set. Make sure item 19 is also there otherwise the pin will work loose!

[Tonybolony]

Ok, Cheers!

[AndyP]

There is a seperate pin in the locking kit I bought. I havn't checked it yet but I think it goes through the pump pulley and locks it to the pump?

http://www.ebay.co.uk/itm/2906938570...84.m1497.l2649

[Christophski]

It may just be a direct replacement.