Volkswagen Workshop Service and Repair Manuals

Sealing quantity adjuster Special tools and workshop equipment required t  Torque wrench -V.A.G 1331- t  Additional bracket -T10108/1- t  Triangular wrench -T 10366- t  Vehicle diagnosis, testing and information system -VAS 5051- –  Determine the quantity injected by the injection pump as follows: Test prerequisites Mechanical engine basic setting OK. Toothed belt tension OK (camshaft drive toothed belt) → 4-cyl. diesel engine, mechanical system; Rep. Gr.15 Coolant temperature must be at least 80 °C. Procedure –  Connect vehicle diagnosis, testing and information system -VAS 5051- → Chapter. When doing this the engine must be running at idling speed. –  Select “self-diagnosis” operating mode. –  Press “Engine electronics” button on display. –  Select “Read measured value block” button on display. –  Select “1 - Display group 1” on keypad in display. –  Viewed from top, observe value in second position. (corresponds to 2.2...9 mg/stroke). –  Note injected quantity value. –  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 -A- to 20 Nm.

–  Via additional bracket -T10108/1-, secure injection pump in vice.

–  Mark position of quantity adjuster versus pump housing with a scriber mark -arrow-. –  Remove cable from fuel shut-off valve -N109- → Anchor incl. bracket. –  Unscrew bolts -A-.

–  Unscrew special bolt -B- with triangular wrench -T 10366-. –  Swivel quantity adjuster completely to side.   Note Pay attention to corrosion and deposits in area of flange.

–  Carefully lever old seal from seat and renew. Ensure “lug”-arrow- is seated correctly.

–  Carefully position quantity adjuster onto injection pump.   Caution Ensure that ball stud of quantity adjuster -1- engages properly in recess of quantity slide valve -2-. –  Loosely tighten quantity adjuster securing bolts hand-tight. –  Bring quantity adjuster to “scriber mark”. –  Tighten securing bolts -omit special bolt- diagonally to 9 Nm. –  Unscrew quantity adjuster cover securing bolts and remove cover.   Note Pay attention to corrosion and deposits in area of flange.

–  Carefully lever old seal from seat and renew. Ensure “lug”-arrow- is seated correctly. –  Position cover onto injection pump. –  Position securing bolts and tighten to 9 Nm. –  Install union for return → Item and tighten to 27 Nm. –  Install injection pump → Chapter and fill via return line using diesel extractor -VAS 5226-.   Note After loosening quantity adjuster, quantity injected must be checked and corrected if necessary → Chapter.