VW Passat & Audi A4 1990-2000

Injection Pump

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REMOVAL & INSTALLATION
1994-1997 VW Passat 1.9L


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Fig. Showing the special required tools for injector pump removal and installation



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Fig. Indicating proper positioning for TDC and installing the camshaft blocking bar

  1. Rotate the crankshaft to TDC for the No.1 cylinder (arrow).
  2.  
  3. Lock the crankshaft with a setting bar.
  4.  
  5. To centralize the setting bar (2065A), turn the crankshaft so one end of the bar contacts the cylinder head.
  6.  
  7. Using a feeler gauge, measure the gap at the other end of the setting bar.
  8.  
  9. Place a feeler gauge, equal to half the measured gap, between the setting bar and cylinder head.
  10.  
  11. Turn the camshaft until the setting bar contacts the feeler gauge. Place a second feeler gauge, of the same thickness, at the other end between the setting bar and the cylinder head.
  12.  
  13. Remove the toothed belt from the camshaft and injection pump sprockets.
  14.  
  15. Remove the injection pump sprocket mounting bolt.
  16.  



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Fig. Installing the injection pump sprocket-pulling tool.

  1. Loosen the puller arms and raise them up.
  2.  
  3. Insert the puller arms through the injection pump holes in the holes in the sprockets and tighten.
  4.  
  5. Put the injection pump sprocket under tension using the puller.
  6.  
  7. Release the injection pump sprocket from the tapered shaft by tapping on the puller screw bolt. Hold the sprocket so it doesn't fall off.
  8.  
  9. Remove all fuel lines from pump and cover openings with a clean cloth.
  10.  


CAUTION
Fire Hazard: Do NOT smoke of have anything in the area that can ignite diesel fuel.


NOTE
Use special tubing wrenches to remove the high-pressure fuel lines.

  1. Unplug fuel cut-off valve and cold start wiring connector.
  2.  
  3. Remove the engine shutoff cable.
  4.  
  5. Detach the accelerator and the cold start accelerator cable.
  6.  



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Fig. Identifying the console mounting bolts

  1. Remove all mounting bolts from console (arrows).
  2.  
  3. Remove the bolt from the rear support (arrow).
  4.  


WARNING
Do NOT loosen the injection pump head mounting bolts. Loosening these bolts side-loads the head and will cause the distributor plungers to fracture.

  1. Remove the injector pump.
  2.  



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Fig. Showing the rear support mounting bolt

To install:

  1. Install the injection pump into the mounting bracket and the tighten mounting bolt on the rear support with conical nut.
  2.  
  3. Align the injection pump to its central position in mounting bracket elongated holes and secure hand tight.
  4.  


NOTE
The injection pump timing is set dynamically with a proper scan tool.

  1. Install the injection pump sprocket and lock in position with the lock pin. Observe that the lock washer is properly seated.
  2.  



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Fig. Installing the injection pump lock pin

  1. Tighten the mounting nut to 41 ft. lbs. (55 Nm).
  2.  
  3. Loosen the camshaft sprocket securing bolt one-half turn.
  4.  
  5. Place a drift through the hole in the rear of the toothed belt guard and release the camshaft sprocket from the taper by tapping it lightly with a hammer.
  6.  
  7. Remove the camshaft sprocket.
  8.  
  9. Make sure that the TDC mark on the flywheel and the reference marks are aligned.
  10.  
  11. Place the toothed belt on the injection pump sprocket and tensioning roller.
  12.  
  13. Fit the camshaft sprocket into the toothed belt and secure the sprocket.
  14.  
  15. Install the idler roller.
  16.  
  17. Remove the locking pin from the injector pump sprocket.
  18.  



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Fig. Tensioning and aligning the toothed belt

  1. To properly tension the toothed belt, use a pin wrench on the eccentric and turn it clockwise until the notch and the raised mark arrows align.
  2.  
  3. Tighten the securing nut to 15 ft. lbs. (20 Nm).
  4.  
  5. Check the TDC mark on the flywheel for alignment.
  6.  
  7. Tighten the camshaft sprocket securing bolt to 33 ft. lbs. (45 Nm).
  8.  
  9. Remove the setting bar.
  10.  
  11. Fill the injection pump with clean diesel fuel through the return line fitting.
  12.  
  13. Reconnect the injector line, fuel lines and electrical wiring.
  14.  
  15. Install the toothed belt guard, cylinder head cover and air cleaner.
  16.  
  17. Turn the crankshaft 2 complete turns in the direction of engine rotation and again check the toothed belt tension.
  18.  
  19. Check the ignition timing.
  20.  
  21. Check the idle speed and governed speed.
  22.  

1998 VW Passat 1.9L

WARNING
Fire Hazard: Do NOT have anything in the area that can ignite diesel fuel.


NOTE
This procedure uses required special tools, operating instructions, test and measuring tools, as well as some special auxiliary tools.

  1. Position the hood lock carrier in service position.
  2.  
  3. Unbolt all fuel lines at the fuel pump.
  4.  


NOTE
Use 3055 tubing wrench, or equivalent, to remove the high-pressure fuel lines.


NOTE
Cover all fuel system openings with a clean cloth or suitable plugs to prevent entry of dirt.

  1. Press a ribbed belt tensioning roller onto the stop, using a box-end wrench in the direction of the arrow.
  2.  



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Fig. Removing the toothed belt

  1. Remove the upper toothed belt guard.
  2.  
  3. Position the crankshaft at TDC for No. 1 cylinder.
  4.  
  5. Lock the camshaft using setting bar.
  6.  



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Fig. Removing the toothed belt

  1. Centralize the setting bar as follows:
  2.  
    1. Turn the crankshaft so one end of the setting bar contacts the cylinder head.
    2.  
    3. Using a feeler gauge, measure the gap at the other end of the setting bar.
    4.  
    5. Place a feeler gauge equal to half that gap between the setting bar and the cylinder head
    6.  
    7. Turn the camshaft until the setting bar contacts the feeler gauge.
    8.  
    9. Place another feeler gauge of the same thickness at the other end between the setting bar and the cylinder head.
    10.  

  3. Remove the injection pump sprocket mounting bolts (arrows).
  4.  



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Fig. Removing the injection pump sprocket bolts


WARNING
Do NOT allow the hub nut (1) to be loosened under any circumstance. Otherwise, the injection pump basic setting will be altered and cannot be reset with normal workshop equipment.

  1. Remove the tensioning roller nut.
  2.  
  3. Relieve the tooth belt tension and remove the camshaft and injection pump sprockets.
  4.  
  5. Disconnect the quantity adjuster connector and unclip the connector from the retainer.
  6.  
  7. Remove the mounting bolts from console (see arrows in illustration).
  8.  



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Fig. Removing the mounting bolts from the console

  1. Remove the bolt from the rear support.
  2.  
  3. Remove the injection pump.
  4.  

To install:

  1. Position the injection pump into the console and tighten the mounting bolt on rear support first.
  2.  
  3. Insert the front securing bolts and tighten all bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the bolts for mounting the injection pump sprocket to hub, but Do NOT tighten.
  6.  
  7. Align the injection pump sprocket to the central position in the elongated holes.
  8.  
  9. Lock the injection pump sprocket with pin 3359.
  10.  



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Fig. Locking the injection pump sprocket with pin 3359


NOTE
The pin bore must have a gap of approximately 3mm to the hub.

  1. Loosen the camshaft sprocket mounting bolt a half turn.
  2.  
  3. Place a drift through the hole in the rear of the toothed belt guard and release the camshaft sprocket from the camshaft tapered shaft, with a gentle blow from a hammer.
  4.  
  5. Take off the camshaft sprocket.
  6.  
  7. Check whether TDC mark on the flywheel and reference mark are aligned.
  8.  
  9. Place the toothed belt on the injection pump sprocket and the tensioning roller.
  10.  
  11. Fit the camshaft sprocket into the toothed belt and secure the sprocket so that the camshaft can still turn.
  12.  
  13. Tension the toothed belt, using pin wrench (V159) on the eccentric, turning it clockwise until the notch and raised mark align.
  14.  



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Fig. Tensioning the toothed belt using pin wrench

  1. Tighten the securing nut to 15 ft. lbs. (20 Nm).
  2.  
  3. Check for proper alignment of the TDC mark on the flywheel.
  4.  
  5. Tighten new mounting bolts for the injection pump gear to 15 ft. lbs. (20 Nm).
  6.  
  7. After the dynamic test for "start of injection," the bolts must be retightened 1 / 4 turn.
  8.  


NOTE
The mounting bolts may be turned only one time, since it involves "stressed" fasteners.

  1. Tighten the camshaft sprocket mounting bolt to 33 ft. lbs. (45 Nm).
  2.  
  3. Remove the alignment gauge, 2065A, from the camshaft and remove the locating pin, 3359, from the injector pump gear.
  4.  
  5. Turn the crankshaft 2 rotations, in the engine direction, until the crankshaft is at TDC for cylinder No. 1.
  6.  
  7. Reconnect the fuel injection lines and electrical wiring.
  8.  
  9. Fill the injection pump with clean diesel fuel through the return line union.
  10.  
  11. Install the toothed belt guard and cylinder head cover.
  12.  
  13. Dynamically check the "start of injection" cycle; adjust if necessary.
  14.  

TESTING & ADJUSTMENTS
All Models
Dynamic Injection Timing

Dynamic injection timing and Inspection requires specialized scan tool, VAG 1551/2, or equivalent. Testing should be performed by trained technicians.


NOTE
Dynamic checking and correcting injection timing is only possible through the scan tool function 04 "Engine Basic Setting."


NOTE
Check injection timing after replacing toothed belt, loosening the injection pump bolts or toothed belt sprockets. Adjust if necessary.


NOTE
Before setting the dynamic injection time, be certain that the "Basic Engine Setting" and toothed belt tension are correct.

  1. Install a proper scan tool and follow the tool's recommended steps to get to "Injection Timing."
  2.  
  3. If the setting is not within the "mean value," the pump must be readjusted using the following process:
  4.  
    1. Loosen the injector pump mounting bolts about 1 turn; leave the easiest bolt to reach until the last.
    2.  
    3. Hold the injection pump by hand, applying pressure in the direction to be rotated.
    4.  



NOTE
If injection pump is advanced, turn the pump in the direction of engine rotation. If the injection pump is retarded, turn the pump against the direction of rotation.

  1. Carefully loosen the last mounting bolt until the pump can be rotated slightly, and then retighten the securing bolt.
  2.  
  3. Verify that the readings are within the "mean value." If not, adjust the pump again until the "mean value" is obtained.
  4.  
  5. Tighten the injection pump mounting bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Recheck the injection timing.
  8.  

Manual Injection Timing


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Fig. Installing injection pump timing tool 2068A

  1. Make sure the pump control lever is fully against the low idle stop. If equipped with a manual cold start knob, make sure the knob is all the way in against the stop.
  2.  
  3. Install adjusting gauge 2068A, as shown.
  4.  
  5. Set the adjusting gauge to 96mm. The reference point is the graduation mark on the left side of the vernier scale (arrow A ).
  6.  
  7. Rotate the crankshaft until the TDC mark on the flywheel is aligned with the tip of the adjusting tool (arrow B ).
  8.  



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Fig. Installing injection pump timing tool 2066

  1. Remove the center plug on the pump head and install the adapter tool VW-2066, or equivalent, and a dial indicator. Preload the dial indicator to 2.5mm.
  2.  
  3. Slowly turn the engine counterclockwise until the dial gauge stops moving, and then zero the dial indicator. This is the bottom of the pump stroke.
  4.  
  5. Turn the engine clockwise until the TDC mark on the flywheel aligns with the pointer on the bell housing.
  6.  
  7. The dial indicator should read 0.75-9.85mm (0.0374-0.0413 inches).
  8.  
  9. If any adjustment is required, remove the timing belt cover and loosen the pump mounting bolts, without turning the engine.
  10.  
  11. Turn the pump body to make the dial indicator read 1.00mm (0.0394 inches).
  12.  
  13. Tighten the mounting bolts to 18 ft. lbs. (25 Nm) and turn the engine backward about 1 turn. Turn the engine forward to TDC of No. 1 cylinder and recheck the dial indicator.
  14.  
  15. When the correct setting is reached on the dial indicator, reinstall the belt cover and the center plug on the pump. Use a new copper gasket.
  16.  

 
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