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Volkswagen Workshop Service and Repair Manuals

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Injectors - remove and install > < Injection pump - remove and install|Removal

Polo Mk4

Installation
Installation
–  Install injection pump on compact support and initially fasten it to rear support with fastening nut.
   
–  Install fastening screws -1- and tighten at 30 Nm.
  N23-0387
–  Slightly tighten indented belt gear with fastening screws -1- to cube.
–  Lock injection pump gear with adjusting punch 3359.
–  Align injection pump gear on central position in the oblong holes.
–  Loosen fastening screw of command shaft gear in 1 turn. To loosen fastening screw, fasten command shaft gear with counter support 3036.
  Note
To loosen and tighten command shaft gear, never use command shaft rule -T10098- as counter-support! Use counter-support 3036.
  N13-0272
–  Place Two armed puller -T40001- with 1-brace clamp -T40001/2--A- and 2-brace clamp -T40001/3--B- in the center of command shaft gear and remove it. For this procedure, use as counter-support a fork wrench-C-.
–  Remove command shaft gear.
–  Check if top center-marking on steering wheel aligns with reference marking.
–  Install indented belt over injection pump gear and tension pulley.
–  Install command shaft gear on indented pulley and fasten gear to command shaft so that it can be turned.
–  Adjust indented belt → Chapter.
–  Connect injection tubes, fuel supplying hose and all letter connections.
  M13-0002
Fill injection pump with diesel as follows.
–  Screw adapter -V.A.G 1318/10- on injection pump return hole.
–  Connect Hand-operated vacuum pump -V.A.G 1390/- with about 1 m of transparent plastic hose to the adapter.
–  Activate Hand-operated vacuum pump -V.A.G 1390/-, until fuel comes out of return hole. Do not pull fuel to the vacuum pump.
–  Remove adapter and connect fuel return hose.
–  Dynamically check injection start and regulate if necessary → Chapter, adjust functions and components.
  A23-0005

Injectors - remove and install > < Injection pump - remove and install|Removal