Diesel injection pump, servicing: Notes
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.
CAUTION:
Observe rules of cleanliness, see RULES OF CLEANLINESS
The following injection pump components can be replaced:
- Throttle lever/return spring. See DIESEL INJECTION PUMP THROTTLE LEVER/RETURN SPRING, REMOVING AND INSTALLING
- Throttle lever bushing - 9 -, throttle lever O-ring - 10 - and gasket - 13 - between pump cover and housing. See THROTTLE LEVER BUSHING IN PUMP COVER, PUMP COVER GASKET AND O-RING FOR THROTTLE LEVER SHAFT, REPLACING
- O-ring - 24 - for residual fuel delivery adjusting screw. See O-RING FOR RESIDUAL FUEL DELIVERY ADJUSTING SCREW, REPLACING
- O-ring for idle speed boost shaft. See O-RING FOR IDLE SPEED BOOST SHAFT, REPLACING
- O-ring - 15 - for Injection Start Positioner -N165-. See O-RING FOR IDLE SPEED BOOST SHAFT, REPLACING
- O-rings - 34 - and - 37 - for CSA lever and cover. See O-RINGS FOR COLD START ACCELERATOR (CSA) LEVER AND COVER, REPLACING
The following list pertains to Fig 1 .
- Circlip
- Pry off with screwdriver
- Compression spring
- Upper spring plate
- 10 Nm (7 ft lb)
- Pump cover
- Thrust washer
- Shaft
- For idle speed boost
- Idle speed boost spring
- Detach when removing pump cover
- Do not overstretch
- Bearing bushing
- O-ring
- Always replace
- Thrust washer
- Throttle lever shaft
- Press out with handle of screwdriver
- Gasket
- Always replace (see THROTTLE LEVER BUSHING IN PUMP COVER, PUMP COVER GASKET AND O -RING FOR THROTTLE LEVER SHAFT, REPLACING ) without replacing bearing
- Shim
- O-ring
- Always replace, see O-RING FOR IDLE SPEED BOOST SHAFT, REPLACING
- Injection timing spring
- Injection timing cover with Injection Start Positioner - N165-
- 10 Nm (7 ft lb)
- 10 Nm (7 ft lb)
- Idle speed throttle lever
- Lower spring cover
- Thrust ring
- O-ring
- O-ring
- Always replace, see O-RING FOR RESIDUAL FUEL DELIVERY ADJUSTING SCREW, REPLACING
- Washer
- Adjustment rod
- For idle speed
- Fuel delivery adjusting screw
- Mark installation position
- Circlip
- Spring washer
- Washer
- Cold Start Accelerator (CSA) lever
- Mark installation position
- Retainer
- For CSA lever - 31 -
- Thrust ring
- O-ring
- Always replace, see O-RINGS FOR COLD START ACCELERATOR (CSA) LEVER AND COVER, REPLACING
- 10 Nm (7 ft lb)
- Cover
- For CSA mechanism
- O-ring
- Always replace, see O-RINGS FOR COLD START ACCELERATOR (CSA) LEVER AND COVER, REPLACING