T4 2.5TDI pump timing

[jets]

Well I finally bit the bullet & changed the pump timing belt,idler & tensioner.
It was forced on me really. When I bought my van it made a slight noise from the pump belt area until it was run for a while when it would go quiet. Around 2 weeks ago when I needed the large capacity of the van, I started it & then had to shut it down straight away because of this much louder noise.
I already had the laptop & plug in cable but had to spend US$99 to register with Ross Tech. I had already made the camshaft sprocket holder, based on VW tool 3036.
After reading Simon Baxter's writeup & the info in Elsa Win, I was ready to go.
http://www.brick-yard.co.uk/VehicleS...ing/Timing.htm

My local VW parts supplier[IMPARTS] had the parts in stock.
Belt 074 130 113 J [optibelt] cost $33
Tensioner 074 130 195 B [same manufacturer as original, made in Canada in INA box] $113.72 & idler 074 130 245 [febi bilstein brand] $80.65.

Before I removed anything I plugged the computer in & the timing was too far retarded to be shown on the timing graph. Great.
I removed the rocker cover to establish the camshaft position which I learned later wasn't necessary because the sprocket has a mark on the edge which is on the top when the engine pos. is at No1. It gave me a chance to clean it properly from previous careless oil spills.
An inspection of all the parts showed that the idler brg was a bit suss, the belt & tensioner looked good. Naturally I still replaced all the parts as they had done 113,000km.

The timing is checked at idle but the temp must be above 85C.
I left the computer running while I made the adjustment to the cam. sprocket but the temp dropped fairly quickly & after the adjustment it still said it was retarded. What I should have done was go back to the temp readout & waited until the temp was above 85C before looking at the timing graph.
After some trial & error I had success. There is a fair amount of turning the crankshaft & locking the pump & unlocking again at the right time & having a friend with me was a help & also moral support.
When the weather warms again I will do the main cambelt,water pump, tensioner etc that was done some 40,000km ago. I know I will need to check the timing again but next time should be easier. Not too hard a job once you know what has to be done but never the less very time consuming.