Injection Pump
Injection Pump, Removing and Installing
Special tools
- 3098 Lever camber adjustment
- V159 Pin wrench
- 3359 Rig pin
- VAG1318/10 Adapter
- 3418 Adjustment guide
- VAG1390 Hand vacuum pump
- 2068A Adj. gauge TDC
- 3035 Injector line wrench
- VAG1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb) or equivalent
Removing
WARNING! Fire hazard! Do NOT have anything in the area that can ignite diesel fuel
- Unbolt all fuel lines at fuel pump.
NOTE: Use 3035 tubing wrench to loosen the high pressure fuel lines.
- Cover openings with a clean cloth.
- Remove connecting line between charge air cooler and intake manifold.
- Remove upper toothed belt guard and valve cover.
- Remove vacuum pump for brake servo.
- Turn crankshaft to cyl. 1 TDC -arrow-.
- Turn crankshaft to cyl. 1 TDC -arrow-
- for Automatic transmission
Manual transmission
- Install 2068A TDC gauge as shown.
- Set adjustment device to 96 mm -arrow A-.
Left-hand notch of the vernier scale is the reference point.
- Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-.
Automatic transmission
- Install 2068A TDC gauge as shown.
- Set adjustment device to 30 mm -arrow A-.
Left-hand notch of the vernier scale is the reference point.
- Turn crankshaft until TDC marking on drive plate aligns with point of setting device - arrow B-.
Continuation for All
- Lock camshaft with setting bar.
- Centralize setting bar as follows:
Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge, establish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of same thickness, at the other end between the setting bar and cylinder head.
- Remove injection pump sprocket mounting bolts -1-.
CAUTION! Do not loosen hub nut -2-for ANY reason. Otherwise, the Diesel injection pump basic setting will be altered and cannot be reset with normal workshop equipment.
- Remove tensioning roller nut.
- Relieve tooth belt tension then remove camshaft and injection pump sprockets.
- Disconnect Quantity adjuster harness connector and unclip connector from retainer.
- Remove mounting bolts from assembly bracket -1-.
- Remove bolt from rear support -arrow-
- Remove Diesel injection pump.
Installing
- Insert injection pump into assembly bracket then tighten mounting bolt on rear support with conical nut first.
- Insert front mounting bolts.
tighten to 25 Nm (18 ft lb)
- Install new bolts -arrows- to mount injection pump sprocket to hub but do not tighten.
- Align injection pump sprocket to central position in elongated holes.
- Lock injection pump sprocket using 3359 pin.
- Loosen camshaft sprocket mounting bolt a half turn.
- Place a drift through hole in rear of toothed belt guard and release camshaft sprocket from camshaft taper with blow from hammer.
- Remove camshaft sprocket.
- Check whether TDC mark on flywheel and reference mark are aligned.
- Place tooth belt on injection pump sprocket and tensioning roller.
- Install camshaft sprocket into toothed belt and secure sprocket such that the camshaft can still turn.
- Tension toothed belt using pin wrench (e.g. Matra V159) on eccentric and turning clockwise until notch and raised mark align -arrows-.
NOTE: Make sure retaining hook is correctly seated in toothed belt guard.
- Tighten mounting nut.
20 Nm (15 ft lb)
- Check TDC mark on flywheel again.
- Tighten new mounting bolts for injection pump sprocket.
20 Nm (15 ft lb)
NOTE:
After dynamically checking the injection timing, tighten the bolts an additional 1/4 turn (90°).
The mounting bolts (stretch design) may only be used once.
- Tighten camshaft sprocket mounting bolt.
45 Nm (33 ft lb)
- Remove 3359 locking pin.
- Remove 3418 setting bar from camshaft.
- Turn crankshaft two rotations in direction of engine rotation until crankshaft is set to cyl. 1 TDC again.
- Reconnect injection lines, fuel supply line and electrical wiring.
Fill injection pump with Diesel fuel as follows.
- Screw 1318/10 adapter into injection pump return/supply opening.
- Connect VAG1390 hand vacuum pump to adapter using approx. 40 inches of transparent plastic hose.
- Operate vacuum pump until fuel flows out of return/supply opening.
Do not draw fuel into vacuum pump.
- Remove adapter and connect return/supply line.
- Install valve cover and vacuum pump.
- Dynamically check Start of injection and adjust if necessary.