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Sealing injection timing device cover > < Checking and adjusting quantity injected

Golf Mk4

Sealing distributor head
Sealing distributor head
Special tools and workshop equipment required
t  Torque wrench -V.A.G 1331-
t  Additional bracket -T10108/1-
–  Remove injection pump → Chapter.
–  Dismantle union for return → Item and drain injection pump by holding it with return bore pointing downwards. Catch escaping fuel.
–  Attach additional bracket -T10108/1- to injection pump flange and tighten bolts to 20 Nm.
   
–  Secure injection pump in vice as shown.
–  Remove retaining plate -A-.
–  Remove cable from fuel shut-off valve -N109- incl. bracket -B-.
  N23-10111
–  Carefully loosen distributor head securing bolts -arrows- diagonally and remove bolts.
  Caution
Never pull distributor head out upwards, as pressure rollers otherwise fall into injection pump housing and repair is then impossible. Injection pump must be renewed in this case.
  N23-10112
–  Remove visible, old seal -arrow- by carefully pulling from seat and opening using a suitable tool. Do not scratch sealing surface.
–  First position new seal behind fuel shut-off valve -N109- , then pull carefully over distributor head and allow to roll into groove.
  Caution
Subsequent tightening of distributor head securing bolts must be carried out in small steps under all circumstances, as distributor head may otherwise tilt within injection pump. In this case, the renewed seal is immediately damaged and leaking again!
–  Position securing bolts and carefully and diagonally bolt distributor head back into position in very small steps.
–  Tighten securing bolts to 12 Nm.
–  Bolt retaining plate and cable of fuel shut-off valve -N109- back on.
–  Install injection pump → Chapter and fill via return line using diesel extractor -VAS 5226-.
  N23-10113

Sealing injection timing device cover > < Checking and adjusting quantity injected