Checking and adjusting
WARNING: This page is about a different car, the 1996 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
- Unscrew plug from injection pump head.CAUTION:
- Always use a new seal when installing plug.
- Tightening torque: 15 Nm (11 ft lb).
- If leaks persist, the plug may be tightened to a maximum of 25 Nm (18 ft lb).
- Thread in adapter and small dial indicator (measuring range 0-3 mm) in place of plug. Preload dial indicator to about 2.5 mm.
- Slowly rotate crankshaft counter-clockwise (opposite direction of normal engine rotation) until dial indicator pointer no longer moves.
- Set dial indicator to "0" with approx. 1 mm preload.
- Rotate crankshaft in direction of engine rotation (clockwise) until TDC marking on flywheel is aligned with reference mark on clutch housing.
- Read plunger stroke on dial indicator.
Specifications:
- Checking: 0.73-0.87 mm stroke
- Adjusting: 0.80 0.02 mm stroke
CAUTION:
Do not adjust the injection pump if the measurement falls within the tolerance range specified for "Checking."
- To adjust, slacken the three bolts on injection pump bracket and mounting bolt for rear support.
- Adjust until dial indicator reading matches specified setting by turning injection pump with adjusting lever 3210.
- Specification:
Adjusting: 0.80 0.02 mm stroke
- Tighten mounting bolts.
- Tightening torque: 25 Nm (18 ft lb)