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Injection start: checking and dynamically adjusting > < Removing

Leon Mk2

Installing
Installing
–  Position the injection pump in the console, first locking the securing bolt of the rear support with the conical nut.
–  Centre the injection pump in the console's slotted holes and hand-tighten the fixing bolts of the pump.
  Note!
The start of injection is dynamically adjusted with the -V.A.G 1551- or -V.A.G 1551- kit.
   
–  Install the injection pump toothed wheel and immobilise it with tool -U-20003-.
  Note!
When placing the toothed wheel, ensure that the key is correctly positioned.
–  Tighten the securing nut to 55 Nm.
–  Loosen camshaft sprocket securing bolt 1/2 turn.
  Note!
The adjusting ruler should never be used as a retaining tool to loosen and secure the camshaft wheel. Use tool -T20018A-.
  E01-0163
–  Pass a drift through the opening in the rear protector of the toothed belt and separate the camshaft sprocket from its cone with a hammer blow.
–  Remove the camshaft sprocket.
  E13-0043
–  Check to see if TDC mark on fly wheel and the reference mark coincide.
–  Check that the camshaft is in the TDC position. To do this, check that the adjusting ruler is positioned correctly and that the -U-20003- tool is blocking the toothed wheel of the injection pump.
–  Place the distribution belt on the toothed wheel of the injection pump and the tensioning roller, position the camshaft's toothed wheel on the distribution belt and secure it to the camshaft in such a way that it can still turn.
–  Install the idler roller.
–  Remove the -U-20003- tool from the injection pump sprocket.
  N13-0049
–  Tension toothed belt. To do so turn pin wrench -U-30009A- clockwise in the eccentric of the tensioning roller until the groove and the projection -arrows- face each other.
  Note!
If the eccentric has been turned too far, the tensioning roller will have to be completely slackened and tightened again. The eccentric should not simply be wound back the distance that it had been overwound.
–  Tighten securing nut to 20 Nm.
–  Tighten the camshaft toothed wheel securing bolt to a torque of 45 Nm.
–  Remove the adjusting ruler from the camshaft.
–  Turn the crankshaft two turns in the direction of engine rotation until cylinder 1 TDC is again reached.
–  Ckeck if coincide: The OT (PMS) mark on the flywheel. The adjusting ruler on the camshaft The -U-20003- tool in the injection pump sprocket. Tensioning roller adjuster (notch/projection)
–  If the notch does not coincide with the projection, the tensioning roller must be re-tensioned. To do this, lock the tensioner roller with tool -U-30009A-, release the securing bolt, turn the eccentric of the tensioning roller clockwise until the cut-out and the projection coincide, then tighten the securing bolt to 20 Nm.
–  Turn the crankshaft two turns in the direction of engine rotation until cylinder 1 TDC is again reached.
–  Repeat the check.
–  Connect the injection and fuel pipes and the electrical cables.
  N13-0027
Fill the injector pump with petrol as follows:
–  Screw on adaptor -V.A.G 1318/10- to the return opening on the injector pump.
–  Couple the adaptor to the manual vacuum pump -SAT-1390- with the help of a clear plastic hose approx. 1 m in length.
–  Work the manual vacuum pump until fuel comes out of the return hose. The fuel must not reach the vacuum pump.
–  Remove the adaptor and couple the return fuel hose.
–  Fit the toothed belt protector, the cylinder head cover and the air filter.
–  Connect the negative terminal of the battery.
–  Check and adjust dynamically the injection start → Chapter.
  E23-0096

Injection start: checking and dynamically adjusting > < Removing