Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Setting bar 2065 A
• ◆ Torque wrench V.A.G 1331 (5...50 Nm)
• ◆ Pin wrench Matra V159
• ◆ Ring spanner 3035

For one piece injection pump sprocket:

• ◆ Pin 2064
• ◆ Puller 3032

For two-part injection pump sprocket:

• ◆ Pin 3359
• ◆ Spade terminal release tool

Engines without semi-automatic tensioning roller:

• ◆ V- and toothed belt test unit VW 210

Injection pumps with one piece injection pump sprocket

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow-.
• ‒ 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 setting bar and cylinder head.
• ‒ Remove toothed belt from camshaft and injection pump sprockets.
• ‒ Remove injection pump sprocket securing nut.

• ‒ → Loosen puller arms and offer up.
• ‒ Locate puller arms through holes in injection pump sprocket and tighten.
• ‒ Place injection pump sprocket under tension with puller.
• ‒ Release injection pump sprocket from injection pump taper by tapping on spindle of puller -arrow- (thereby hold sprocket so that it does not fall off).
• ‒ Remove all fuel pipes from pump and cover openings with clean cloth.

Note:

Use open ring spanner 3035 to remove high pressure fuel pipes.

• ‒ Remove engine shut-off cable.
• ‒ Detach accelerator and cold start accelerator cable.

• ‒ → Remove securing bolts from console -arrows-.

Note:

On no account should the bolts holding the injection pump head be loosened. Loosening these bolts allows the head to cant and caurses the distributor plungers to fracture.

• ‒ → Remove bolt from rear support -arrow-.

Installing

• ‒ Install injection pump and align to centre position in the flange elongated holes.
  Tightening torque:
       Securing bolts:          25 Nm
       Fuel pipes:          25 Nm
       Injection pump sprocket:     45 Nm

Note:

Do not interchange fuel supply and return pipe banjo bolts the return pipe banjo bolt has a smaller internal diameter and "OUT" is marked on the hexagon head.

• ‒ → Install injection pump sprocket and lock in position with pin 2064.
• ‒ Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).
• ‒ Check whether TDC mark on flywheel and reference mark are aligned.
• ‒ Place toothed belt on and remove injection pump sprocket locating pin.

• ‒ → Tension toothed belts (turn tensioner with pin wrench e.g. Matra V159 -arrow- to right).
       Scale value: 12 ... 13
  measured between camshaft sprocket and injection pump sprocket.
• ‒ Tighten camshaft sprocket securing bolt to
  45 Nm.
• ‒ Remove setting bar.
• ‒ Turn crankshaft two rotations in engine D.O.R. and again check toothed belt tension.
• ‒ Checking injection timing
• ‒ Checking and adjusting idling speed and governed speed => Page 23-32

Injection pumps with two-part injection pump sprocket

• ‒ Remove air cleaner.
• ‒ Remove upper toothed belt guard.
• ‒ Remove cylinder head cover.
• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow-.
• ‒ 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 setting bar and cylinder head.

• ‒ → Lock injection pump sprocket with pin 3359.
• ‒ Loosen injection pump sprocket securing bolts -1-.
• ‒ Loosen tensioner.
• ‒ Take off toothed belt.
• ‒ Remove all fuel pipes from pump and cover openings with clean cloth.

Note:

Use open ring spanner 3035 to remove high pressure fuel pipes.

• ‒ → Separate multi-pin connector -1- and unclip from retainer.
• ‒ Disconnect earth cable -2-.
• ‒ Separate connections for oil pressure switch, coolant temperature sender and feed wire for glow plugs.

• ‒ → Remove securing bolts from console -arrows-.

• ‒ → Remove bolt from rear support -arrow-.
• ‒ Take off injection pump with multi-pin connector.

Installing

→ If the injection pump is replaced, the spade contacts must be pushed out of the multi-pin connector with the spade terminal release tool.

•      1 -     Spade terminal release tool
•      2 -     Multi-pin connector

Injections pumps supplied as a replacement part, are not fitted with a multi-pin connector. The spade connectors on the wires must be located in the multi-pin connector in accordance with the current flow diagram:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

• ‒ Insert injection pump in console and then tighten securing bolt on rear support with conical nut first.
• ‒ Insert front securing bolts and tighten to 25 Nm.
• ‒ → Fit injection pump sprocket, screw in securing bolts -1- loosely and align to middle position in the elongated holes.
• ‒ Lock injection pump sprocket with pin 3359.

• ‒ → Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).
• ‒ Fit toothed belt to injection pump sprocket and tensioning roller.
• ‒ Fit camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still turn).

• ‒ → Turn tensioning roller with pin wrench (e.g. Matra V159) to right until notch aligns with raised portion (arrows).
• ‒ Tighten lock nut on tensioning roller.
       Tightening torque: 20 Nm
• ‒ Check again whether TDC mark on flywheel and reference mark are aligned.
• ‒ Tighten camshaft sprocket securing bolt to
  45 Nm.
• ‒ Tighten injection pump sprocket securing bolts to
       25 Nm.
• ‒ Remove setting bar.
• ‒ Remove pin.
• ‒ Turn crankshaft two rotations in engine D.O.R. and set again to TDC No. 1 cylinder.

• ‒ → Check whether injection pump sprocket can be locked with pin 3359.

If the injection pump sprocket cannot be locked:

• ‒ Loosen injection pump securing bolts -1-.
• ‒ Turn injection pump sprocket hub until the pin fits.
• ‒ Tighten injection pump sprocket securing bolts to
       25 Nm.

• ‒ Reconnect injection pipes, fuel pipes and electrical wiring.

Note:

Do not interchange fuel supply and return pipe banjo bolts the return pipe banjo bolt has a smaller internal diameter and "OUT" is marked on the hexagon head.

• ‒ Install toothed belt guard, cylinder head cover and air cleaner.