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  Triangle key -T 10366- t  Vehicle diagnosis, testing and information system -VAS 5051- –  Set the injection quantity of the injection pump as follows: Test prerequisites Mechanical basic setting of engine OK. Toothed belt tension OK (toothed belt for camshaft drive) → 4-cyl. diesel engine, mechanics; 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 operating mode “Self-diagnosis”. –  Press “Engine electronics” button on display. –  Press “Read measured value block” button on display. –  Select “1.-.Display group 1” on the keyboard. –  Observe the value see from the top at the second position. (equates to 2.2...9 mg/stroke). –  Make a note of the injection quantity. –  Remove injection pump → Chapter. –  Remove return connection → Item and drain the injection pump by holding it with the return hole down. Catch escaping fuel. –  Remove the additional bracket -T10108/1- on the injection pump flange and tight the bolts -A- to 20 Nm.

–  Secure the injection pump using the additional bracket -T10108/1- in a vice.

–  Mark the position of the quantity adjuster in relation to the pump housing using a scriber -arrow-. –  Remove the cable from the fuel shutoff valve -N109- → Anchor inc. bracket. –  Unscrew bolts -A-.

–  Unscrew the special bolt -B- using triangle key -T 10366-. –  Carefully swing the quantity adjuster completely to one side.   Note Take note of signs of corrosion or deposits in the flange area.

–  Carefully lever the old seal off its seat and replace it. Ensure the “lug” is seated correctly -arrow-.

–  Place the quantity adjuster carefully on the injection pump.   Caution Ensure that the ball pin of the quantity adjuster -1- engages properly in the recess of the quantity adjuster -2-. –  Start the securing bolts of the quantity adjuster loosely by hand. –  Move the quantity adjuster to the “scriber mark”. –  Tighten the securing bolts -with exception of the special bolt- to 9 Nm in diagonal sequence. –  Unscrew the securing bolts of the quantity adjuster cover and remove the cover.   Note Take note of signs of corrosion or deposits in the flange area.

–  Carefully lever the old seal off its seat and replace it. Ensure the “lug” is seated correctly -arrow-. –  Place cover on injection pump. –  Start securing bolts and tighten them to 9 Nm. –  Fit the return connection → Item and tighten it to 27 Nm. –  Install the injection pump → Chapter and fill it via the return line using diesel extractor -VAS 5226-.   Note When the quantity adjuster is loosened, the injection quantity has to be checked and ,where necessary, corrected → Chapter.