Injection Pump, Removing and Installing
INJECTION PUMP, REMOVING AND INSTALLING
Special tools and equipment
- 2068 A TDC setting device
- 3035 Offset wrench
- 3036 Spanner
- 3359 Pin
- 3418 Setting bar
- T10020 Two-hole pin spanner (for vehicles with manual transmission)
- T40001 Two-arm puller
- VAG 1318/10 Adapter
- VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb)
- VAG 1390 Hand vacuum pump
- VAG 1921 Spring-type clamp pliers
- Feeler gauges
- Plastic pipe (transparent approx. 1 m)
Removing
- Remove engine cover.
- Disconnect fuel supply and return lines at injection pump (arrows).
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove injector lines with tool 3035.
NOTE: Always remove two-piece line set as a complete unit. Do not alter the shape of the lines.
- Cover openings with a clean cloth.
- Remove right headlight:
- Remove connecting line between charge air cooler and intake manifold.
- Remove upper part of toothed belt guard.
- Remove cylinder head cover.
- Remove vacuum pump for brake servo.
Engine installed:
- Turn crankshaft to TDC on No.1 cylinder (vehicles with manual transmission).
- Set crankshaft to TDC on No.1 cylinder (vehicles with automatic transmission).
Engine removed:
Vehicles with manual transmission
- Install adjustment device 2068 A as shown.
- Set adjustment device to 96 mm (arrow A). Left-hand notch of vernier scale is reference point.
- Turn crankshaft until flywheel TDC marking aligns with point of setting device (arrow B).
Vehicles with automatic transmission
- Install adjustment device 2068 A as shown.
- Set adjustment device to 30 mm (arrow A). Left-hand notch of vernier scale is reference point.
- Turn crankshaft until TDC marking on drive plate aligns with point of setting device (arrow B).
Continued for all vehicles
- Lock camshaft with setting bar 3418.
- Centralize setting bar as follows:
- Turn camshaft so that one end of setting bar contacts cylinder head.
- Using feeler gauge establish gap at other end of setting bar.
- Place a feeler gauge corresponding to one half of gap between setting bar and cylinder head.
- Turn camshaft until setting bar contacts feeler gauge.
- Place a 2nd feeler gauge, of same thickness, at the other end between setting bar and cylinder head.
- Lock injection pump sprocket with pin 3359.
- Remove injection pump sprocket bolts -1-.
NOTE: DO NOT loosen the hub nut -2-. If nut -2- is loosened the injection pump basic setting will be altered and this cannot be reset with normal workshop equipment.
- Remove tensioning roller nut.
- Relieve toothed belt tension and remove camshaft and injection pump sprockets.
- Disconnect 10-pin connector for injection pump metering unit (arrow) and release connector from retainer.
- Remove securing bolts from compact bracket -1-.
NOTE: DO NOT loosen the hub nut -2-. If nut -2- is loosened the injection pump basic setting will be altered and this cannot be reset with normal workshop equipment.
- Remove bolt from rear support (arrow).
- Remove injection pump.
Installing
- Insert injection pump into compact bracket and then tighten securing bolt on rear support using conical nut first.
- Insert front securing bolts and tighten to 25 Nm (18 ft lb).
- Install injection pump sprocket to hub with new bolts (arrows) but do not tighten.
- Lock injection pump sprocket with pin 3359.
- Align injection pump sprocket to central position in elongated holes.
- Hold camshaft sprocket with counter-hold tool 3036 and loosen camshaft bolt by 1 turn.
NOTE: The setting bar 3418 must not be used as a counter-hold tool when loosening and tightening the securing bolt. The camshaft sprocket must always be held with the counter-hold tool 3036 when loosening or tightening the camshaft bolt.
- Position two-arm puller T40001 with single arm hook -A- and two-arm hook -B- centralized on camshaft sprocket. Counter-hold on puller with open end wrench -C- and pull sprocket off.
- Check whether TDC mark on flywheel and reference mark are aligned.
- Place toothed belt on injection pump sprocket and tensioning roller.
- Install camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still turn).
Vehicles with manual transmission
- Tension toothed belt using two-hole pin spanner on eccentric turning clockwise until notch and raised mark align (arrows).
NOTE: If necessary use a mirror for a visual check.
Vehicles with automatic transmission
- Tension toothed belt by turning eccentric clockwise using a commercially available hexagon key until notch and indicator align.
NOTE: If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must never be turned back when it has been turned too far.
Continued for all vehicles
NOTE: Make sure that the tensioning roller seats correctly in the rear toothed belt guard (arrow).
- Tighten lock nut on tensioning roller.
- Tightening torque: 20 Nm (15 ft lb)
- Check TDC mark on flywheel again.
- Tighten new securing bolts for injection pump sprocket.
- Tightening torque: 20 Nm (15 ft lb)
NOTE:
- After dynamically checking the start of injection, the bolts must be tightened a further 1/4 turn (90°).
- The securing bolts are stretch bolts and must only be used once.
- Hold camshaft sprocket with counter-hold tool 3036 and tighten camshaft sprocket securing bolt.
- Tightening torque: 45 Nm (33 ft lb)
- Remove locking pin 3359.
- Remove setting bar 3418 from camshaft.
- Turn crankshaft two revolutions in direction of engine rotation until crankshaft is set to TDC on No. 1 cylinder again.
- Reconnect injection lines, fuel supply line and electrical wiring.
Fill injection pump with Diesel fuel as follows:
- Thread adapter VAG 1318/10 into return hole in injection pump.
- Connect hand vacuum pump VAG 1390 to adapter with approx. 1 m transparent plastic hose.
- Operate vacuum pump until fuel flows out of return supply opening. Do not draw fuel into vacuum pump.
- Remove adapter and connect return supply line.
- Install vacuum pump.
- Tightening torque: 20 Nm (15 ft lb)
- Install cylinder head cover.
- Tightening torque: 10 Nm (7 ft lb)
- Install upper part of toothed belt guard.
- Dynamically check start of injection and adjust if necessary, Start of Injection, Dynamically Checking and Adjusting