Fuel Injection Pump, Removing and Installing

Removing







- Remove sound dampening pan
- Unscrew mounting bolts -1- left and right
- Tilt radiator and lock carrier out and forward -arrow-
- Remove toothed belt guard from injection pump drive







- Turn crankshaft to cyl. 1 TDC
- Marks on flywheel/clutch housing and injection pump wheel/mounting bracket -arrows- must be aligned







- Lock injection pump sprocket with 2064 locking pin
- Hold injection pump sprocket with 3036 counter-hold tool
- Loosen mounting bolt, remove sprocket/toothed belt
- Loosen injection pump sprocket mounting nut approx. one turn and remove 2064 lock pin







- Pre-tension injection pump sprocket using puller
- Loosen injection pump sprocket from taper by tapping lightly on puller spindle -arrow-
- Unscrew mounting nut and remove injection pump sprocket
- Detach injection pipes, fuel supply line, fuel return line, shut-off line, throttle and Cold Start Accelerator cables


NOTE: Use tubing wrench to loosen injection line.


- Unscrew injection pump mounting bolts from mounting bracket and remove pump
- to remove rear mounting bolt use 180 mm extension with 6 mm socket insert

Installing







- Install injection pump and make sure marks at injection pump flange and mounting bracket are in line -arrows-
- Install mounting bolts and tighten
- 25 Nm (18 ft lb)
- Place injection pump sprocket in position and turn until marks on sprocket and mounting bracket are in line -arrows-
- Lock injection pump sprocket with 2064 mandrel and tighten mounting nut
- 50 Nm (37 ft lb)
- Install toothed belt with injection pump drive sprocket
- Tighten injection pump mounting bolt, ensuring drive sprocket can still be turned by hand







- Check toothed belt tension
- specification: 12 to 13 scale value using VW 210







- If necessary, tension toothed belt to specified value after loosening mounting bolts -arrows- and displacing the mounting bracket with pump
- Remove mandrel from injection pump sprocket







- Screw in adaptor in place of plug, and install small dial gauge (0 to 3.0 mm range) with about 2.0 mm pretension
- Ensure that crankshaft is still at cyl 1 TDC
- Set start of injection as follows


NOTE: To read the dial gauge when turning injection pump drive gear, lift vehicle and turn from below. When checking start of injection by turning crankshaft backward and forward, use a second technician to watch the marks on the flywheel/transmission.







- Turn injection pump sprocket anti-clockwise (opposite to normal direction) -arrow direction A- using 3036 until dial gauge needle stops moving
- Zero gauge
- Turn injection pump sprocket clockwise using 3036 tool -arrow- direction -B- until dial gauge displays:
- 1.00 + 0.02 mm stroke (start of injection)
- Hold injection pump sprocket in this position using 3036 tool
- Hand tighten fixing bolt approx.
- 50 Nm (37 ft lb) approx.


CAUTION!
Re-check start of injection by turning crankshaft back to zero on the dial gauge and forward to TDC (via vibration damper) This check will deviate from the set figure due to toothed belt slip.


- Start of injection must now be corrected again by a second adjustment, taking deviation into account e.g.

- 1st adjustment figure = 1.00 mm
- Figure when checked = 0.93 mm
- Deviation = 0.07 mm
- 2nd adjustment figure = 1.07 mm

- After 2nd adjustment tighten injection pump sprocket
- 100 Nm (74 ft lb)
- Connect fuel injection lines, fuel supply line, fuel return line, cut-off line and throttle cable


CAUTION!
Do not interchange the feed and return line banjo bolts The inside diameter of the return line bolt is smaller and the hex is marked "OUT".


- Adjust idle and maximum engine speeds
- Install toothed belt guard, radiator, lock carrier and engine cover