Injection Pump

Injection Pump, Removing And Installing










Special tools and equipment
- 3098 Camber adjusting lever
- 3359 Rig pin
- T10098 Camshaft bar
- V159 Pin wrench
- VAG 1318/10 Adapter
- VAG 1390 Hand vacuum pump
- 2068 A TDC setting device
- 3035 Injector Line wrench
- VAG 1331 Torque wrench (5...50 Nm)
- 3036 Counter-hold tool
- T40001 Puller
- Plastic pipe (transparent approx. 1 m)

Removing
- Relieve toothed belt tension and take toothed belt off camshaft and injection pump sprockets.

NOTE: The vibration damper/belt pulley, the center and lower toothed belt guard as well as the assembly mounting can remain installed.

- Unbolt all fuel lines at fuel pump.

NOTE:
- To remove injector pipe set, use injector line wrench 3035.
- To not alter the shapes of the bends.

- Cover openings with a clean cloth.
- Disconnect quantity adjuster connector and unclip connector from retainer.







- 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 securing bolts from compact bracket -1-.







- Remove bolt from rear support -arrow-.
- Remove injection pump.

Installing
- Insert injection pump into compact bracket then tighten securing bolt on rear support using conical nut first.
- Insert front securing bolts and tighten to 25 Nm.







- Install injection pump sprocket to hub with securing bolts -arrows- but do not tighten.
- When doing this, observe the different versions of injection pump sprocket securing bolts, See Fig. 1 .
- Lock injection pump sprocket with Rig 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: Never use camshaft bar T10098 as a counter-hold when loosening and tightening the camshaft sprocket. Use counter-hold tool 3036.







- Place puller T40001 with single leg T40001/2 -A- and double leg T40001/3 -B- centrally on the camshaft sprocket and pull it off.
Use an open ended wrench -C- to counter-hold when doing this.
- Remove camshaft sprocket.
- Check whether TDC mark on flywheel and reference mark are aligned.
- Place tooth belt on injection pump sprocket and tensioning roller.
- Fit camshaft sprocket into toothed belt and secure sprocket so that the camshaft can still turn.
- Tensioning toothed belt.
- Reconnect injection pipes, fuel supply pipe and electrical wiring.







Fill injection pump with Diesel 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.
- Dynamically check start of injection and adjust if necessary.


Fig. 1 Types of injection pump sprocket securing bolts







Version -A-: Securing bolts with chamfer on shaft and pointed end - arrows-
- Part number on injection pump sprocket: 038 130 111 A
- Torque setting of securing bolts: 20 Nm + 1/4 turn (90 degree)
- Replace securing bolts

NOTE: The securing bolt -A- is a stretch bolt and must always be replaced.

Version -B-: Securing bolts without chamfer on shaft and without pointed end
- Part number on injection pump sprocket: 038 130 111 B
- Torque setting of securing bolts: 25 Nm
- Securing bolts do not need to be replaced.