Injection pump, servicing: Notes

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Observe rules for cleanliness → Rules for cleanliness
Removing and installing injection pump → Injection pump, removing and installing
Dynamically checking and adjusting injection pump → Start of injection, dynamically checking and adjusting
Always replace seals and O-rings

Fig 1: Exploded View Of Injection Pump Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Oil seal

Always replace

2 - Pipe union, 25 Nm

For supply line
From fuel filter

3 - Injection pump

With quantity adjuster (metering)
With Fuel Temperature Sensor G81 *, checking → Fuel temperature sensor G81 , checking
With Quantity Adjuster N146 *, checking → Modulating piston displacement sensor G149 and quantity adjuster N146 , checking
With Modulating Piston Displacement Sensor G149 *, checking → Modulating piston displacement sensor G149 and quantity adjuster N146 , checking

4 - Fuel shut-off valve N109 */**, 25 Nm

5 - Union

For return

6 - Return line

To control valve/fuel filter

7 - 25 Nm

8 - Injector lines

Tighten to 25 Nm
Remove and install with 3035
Always remove two-part linework complete
Do not alter shape

9 - Line union, 45 Nm

With pressure valve

10 - 25 Nm

11 - Injector

Removing and installing → Injectors, removing and installing
Checking → Injectors, checking
For No. 3 cylinder with Needle Lift Sensor G80 *
Checking needle lift sensor → Needle lift sensor G80 , checking

12 - 20 Nm

13 - Retainer

14 - Mounting

15 - Copper washer

Always replace

16 - 10 Nm

17 - Cold Start Injector N108 */**

Checking injection timing control range → Diesel injection timing control range, checking

18 - Gasket

Always replace

19 - Strainer

Clean strainer if soiled

20 - Timing control cover

If leaking, replace gasket → Injection timing device cover gasket, replacing

21 - Sleeve

With nut

22 - Compact bracket

For injection pump, generator and power steering pump
For vehicles without air conditioner
Removing and installing: → 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
Removing and installing compact bracket on vehicles with air conditioner: → 87 - AIR CONDITIONING

23 - 25 Nm

24 - Injection pump sprocket bolts

Take note of different types and torque settings: Types of injection pump sprocket securing bolts

25 - Injection pump sprocket

Take note of different types (Part No.): Types of injection pump sprocket securing bolts
Removing and installing → Injection pump, removing and installing , Removing and installing injection pump

26 - Nut

For hub
Do not loosen or the injection pump basic setting may be altered. This cannot be reset with normal workshop equipment.