Installing

DIESEL INJECTION PUMP INSTALLING

- Install injection pump and align to center position in the oblong holes at mounting flange.

Tightening torques:
- Injection pump mounting bolts 25 Nm (18 ft lb)
- Fuel lines 25 Nm (18 ft lb)
- Injection pump sprocket 45 Nm (33 ft lb)

CAUTION: Do not mix up the feed line and return line banjo bolts. The inside diameter of the bolt for the return line is smaller and the marking "OUT" appears on the hexagon head.





- Install injection pump sprocket and lock into position using pin 2064.
- Loosen camshaft sprocket bolt one-half turn. Detach camshaft sprocket from tapered end of camshaft by tapping with hammer (using drift through hole in rear belt guard).
- Check whether TDC (Cyl. 1) marking on flywheel is aligned with reference mark.
- Install drive belt and remove locking pin from injection pump sprocket.





- Adjust drive belt tension by turning tensioner pulley clockwise using pin wrench -arrow-, (e.g. Matra V159).
- Measure tension between camshaft sprocket and injection pump sprocket using belt tensioner gauge VW 210
- Gauge scale value: 12-13
- Tighten camshaft sprocket bolt to 45 Nm (33 ft lb).
- Remove setting bar 2065A.
- Turn crankshaft two complete revolutions in direction of engine rotation, then check again that drive belt still has specified tension.
- Check injection pump static timing. Testing and Inspection
- Check and adjust idle speed and maximum engine speed (RPM). Testing and Inspection