Throttle lever bushing in pump cover, pump cover gasket and O-ring for throttle lever shaft, replacing: 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.
NOTE:
- The numbered items in the procedure that follows refer to Figure in DIESEL INJECTION PUMP, SERVICING .
- Removing return spring and throttle lever, see DIESEL INJECTION PUMP THROTTLE LEVER/RETURN SPRING, REMOVING AND INSTALLING .
- Mark position of fuel delivery adjusting screw (e.g. position of screw slot relative to pump cover -arrows-).
- Loosen lock nut, rotate against locking sleeve and unscrew fuel delivery adjusting screw from pump cover.CAUTION:
- The slightest misadjustment of the fuel delivery adjusting screw can cause soot build-up and/or loss of engine power.
- It is important that the adjusting screw is re-installed in the same position. The fuel delivery adjusting screw should NEVER be rotated past the starting position.
- Disconnect fuel return line.
- Using an oil can, draw fuel out of injection pump through return line connection.
- Remove 4 bolts fastening cover.
- Separate idle speed adjustment rod -26- from idle speed boost lever -20- by removing circlip - 1-. See Figure .
- Raise pump cover -5-; press throttle lever shaft - 12 - toward inside of cover (e.g. with handle of screwdriver) when removing cover. See Figure .
- Disconnect spring -8- (e.g. with shop-made wire hook). See Figure .
- Remove pump cover and press out bearing bushing -9-. See Figure .
- Clean pump cover.
- Coat outer diameter of new bearing bushing with D6 and press into cover as far as collar.
- Carefully remove any surplus D6.NOTE: Various types of bushing are available depending on the pump version. Select the correct type by comparing with the old one.
- Install new O-ring -10- for throttle lever. See Figure .
- Insert new gasket -13 - for pump cover (sealing ring is held in place during installation by small protrusions around outside of gasket). See Figure .
- Moisten throttle lever shaft and O-ring with diesel fuel and press into bearing bushing, then install on pump cover.CAUTION: Make sure that the thrust washer -11- for the throttle lever is in position. See Figure .
- Attach spring -8-. See Figure .
- Tighten pump cover.
- Screw in fuel delivery adjusting screw -27 - with new O-ring. See Figure .
- Install return spring and throttle lever, see DIESEL INJECTION PUMP THROTTLE LEVER/RETURN SPRING, REMOVING AND INSTALLING .
- Run engine until warm and check idle speed and maximum engine speed.