Diesel injection pump, removing and installing: Installing
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.
- 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 inserted through hole in rear belt guard).
- Check whether TDC (Cyl. 1) marking on flywheel is aligned with reference mark on clutch housing.
- 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. See DIESEL INJECTION PUMP STATIC TIMING, CHECKING AND ADJUSTING .
- Check and adjust idle speed and maximum engine speed (RPM). See IDLE SPEED, IDLE SPEED BOOST, MAXIMUM ENGINE SPEED (RPM) AND RESIDUAL FUEL DELIVERY, CHECKING AND ADJUSTING .