Passat Wagon L4-1.9L DSL Turbo (AAZ) (1996)
Diesel MFI Pump: Testing and Inspection
Diesel Injection Pump Timing, Checking and Adjusting
DIESEL INJECTION PUMP TIMING, CHECKING AND ADJUSTING
Checking and adjustment conditions
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Toothed belt tension OK.
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Cold Start Accelerator cable must not be pulled out (operating lever of fuel injection pump in 0 position).
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Set engine to TDC (No.1 cylinder).
Engine installed:
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Turn crankshaft until TDC mark on flywheel is aligned with mark on clutch housing.
Engine removed:
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Screw in adjusting tool as shown.
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Set the adjusting tool to 96.0 mm. The reference point is the graduation mark on the left of the vernier scale (arrow A).
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Rotate crankshaft until TDC mark on flywheel is aligned with the tip of the adjusting tool (arrow B).
Checking and adjusting
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Remove plug from injection pump head.
NOTES:
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Always replace plug seal.
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Tightening torque 15 Nm (11 ft lb).
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May be tightened to 25 Nm (18 ft lb) max. if leaks occur.
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Screw in adapter and small dial gauge (measuring range 0-3.0 mm) in place of plug and preload dial gauge to approx. 2.5 mm.