Audi Workshop Service and Repair Manuals

Removing and installing injection pump Removing injection pump –  Obtain radio anti-theft code, then switch off ignition and disconnect battery earth strap. –  Move lock carrier to service position → Rep. Gr.50. –  Remove viscous fan. –  Remove toothed belt covers (front left and right).

–  Remove front section of intake manifold. –  Open oil filler cap.

–  Turn engine until the marking “- OT -” (TDC) is visible on camshaft.   Note Turn over the engine at the central bolt on the crankshaft. –  Unscrew plug for TDC marking from crankcase. The crankshaft is provided with a TDC drilling, which can be felt directly below the plug.

–  Screw locking pin -3242- into threaded hole where plug has been removed, and tighten.

–  Remove vibration damper on injection pump sprocket (bolts -1-).   Note Do NOT loosen nut -2- for injection pump sprocket. Otherwise this would alter the basic setting of the injection pump. The setting cannot be re-adjusted with workshop equipment. –  Mark direction of rotation of toothed belt. The belt can break if it rotates in the opposite direction when refitted.

–  Slacken toothed belt tensioner and take off toothed belt. –  Unplug connector from injection pump. –  Disconnect fuel supply and return pipes from injection pump. –  Cover open connections with a clean cloth. –  Disconnect injector pipes from injectors using open ring spanner -3035-.

–  Unscrew injection pump mountings. –  Lift out injection pump together with injector pipes. –  Disconnect injection pipes. Installing injection pump

–  Mount injection pump on engine and bolt it in place. t  Tightening torque: bolts on crankcase: 20 Nm t  Tightening torque: bolts on toothed belt cover: 10 Nm –  After tightening injection pump mountings, fit injector pipes one at a time, working from bottom to top and secure using torque wrench -V.A.G 1331- and 17 mm open ring spanner attachment (e.g. Stahlwille 733/10). t  Tightening torque: 30 Nm   Note t  Incorrect assembly will distort the taper seats of the pipe unions. (Risk of leaks) t  When tightening the connections, make sure the injector pipes are not twisted or under tension. t  Secure the retaining clips on the injector pipes in their original positions and without tension. –  Secure injector pipes to injectors. t  Tightening torque: 30 Nm

–  Lock injection pump sprocket with diesel injection pump locking pin -3359-.

–  Slacken camshaft sprocket -1- and align centrally in longitudinal holes. –  Fit toothed belt. Pay attention to the direction of rotation as marked upon removal.

–  Tension toothed belt. To do this, turn Allen key anti-clockwise until the markings align, and then tighten the securing nut. t  Tightening torque: 36 Nm –  Tighten bolts at camshaft sprocket. t  Tightening torque: 20 Nm

–  Remove diesel injection pump locking pin -3359-.

–  Remove locking pin -3242-. –  Turn crankshaft two rotations in normal direction of rotation until it is set to TDC of No. 3 cylinder again. –  Recheck markings at toothed belt tensioner. Correct toothed belt tension as necessary.

–  Install vibration damper on injection pump sprocket (bolts -1-). t  Tightening torque: 20 Nm

–  Install front section of intake manifold. t  Tightening torque: 10 Nm –  Fit connector to injection pump. –  Connect fuel pipes. –  Install viscous fan. –  Install lock carrier → Rep. Gr.50. After installing the injection pump, the following steps must be performed: l  Bleed fuel system, otherwise engine will not start → Chapter. l  Dynamically check and adjust commencement of injection → Chapter.