Passat Wagon L4-1.9L DSL Turbo (AAZ) (1996)
NOTE: Ensure that guide bushing -5- engages in shim -8-.
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Install mounting bolt -1- with washer -2- and tighten a few turns.
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Attach load change damping spring -4- and tighten securing bolt -1- to 10 Nm (7 ft lb).
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Check idle speed and engine governed speed and adjust if necessary.
Throttle Lever Bushing, Shaft O-Ring and Gasket, Replacing
WARNING! Fire hazard. Do NOT smoke or have anything in the area that can ignite Diesel fuel!
PUMP COVER THROTTLE LEVER BUSHING, SHAFT O-RING AND GASKET, REPLACING
Removing return spring and throttle lever, refer to "Throttle Lever and Return Spring, Removing and Installing".
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Mark position of fuel delivery adjusting screw relative to pump cover, i.e. screw slot relative to pump cover (arrows).
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Loosen locking nut against the locking sleeve and unscrew fuel delivery adjusting screw from the pump cover.
NOTE: The smallest mis-adjustment of the fuel delivery adjustment screw can cause sooting or loss of engine power. Therefore it is important
that the adjusting screw is re-installed in the same position. On no account may the adjusting screw be screwed in further than the original position.
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Remove fuel return line.
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Wrap a cloth around the fuel pump to absorb any leaking fuel.
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Remove the four cover mounting bolts.
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Separate the idle speed throttle lever from the idle speed adjusting rod by removing the circlip.
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Angle the pump cover slightly to one side, and detach idle speed spring (arrow) using a locally manufactured hook. Do not over tension spring.
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Lift pump cover slightly, press throttle lever shaft (arrow) towards the inside of the cover (e.g. with a screwdriver handle) while removing the
cover.