This work is necessary, for example, when a toothed belt was installed. Special VW 2066 adapter and small "hour indicator", measuring probe with a round dial with a measurement range of 0-3.0 mm (3). You will also need a new O-ring for the plug bolt on the HPFP head (1). Adjusting the injection timing is a precise professional job that can only be carried out in specialized workshops.
The toothed belt tension must be set correctly.
Push in the cold start booster rod.
Set the engine to the TDC position of the first cylinder.
Remove toothed belt cover.
Remove the cap screw on the injection pump head in the middle of the high pressure fuel lines.
Screw in the adapter instead of the blind bolt.
Screw the adapter pusher to the hour indicator.
The dial gauge will tighten to adjust by about 2.5mm of preload.
Lightly strike the pump housing with a small hammer to ensure that the centrifugal regulator returns to its main position.
Slowly turn the crankshaft counterclockwise until the dial indicator no longer moves.
Now set the dial indicator with a suitable pretension of 1 mm to «0».
Rotate the crankshaft clockwise until the BM mark is in line with the mark on the housing.
Read the indicator readings: allowable variation from 0.83 to 0.97 mm of stroke on a 47 kW suction diesel or 0.73-0.87 mm of stroke on a 55 kW turbodiesel.
If this value is not reached, adjustment is necessary.
To do this, loosen both upper bolts on the console and the fixing bolt on the outlet side of the pump on the stand.
Loosen the third fixing bolt on the injection pump through one of the holes in the toothed belt wheel.
By turning the HPP around its axis, it is now possible to adjust the injection moment.
When adjusting the stroke, it should be 0.90 mm on a 47 kW suction diesel and 0.80 mm of stroke on a 55 kW turbodiesel and set as accurately as possible (spread±0.02 mm). Then re-tighten the injection pump mounting bolts to 25 Nm.
Remove the dial indicator with the adapter and screw in the plug bolt with a new sealing ring with a torque of 15 Nm. In case of leaks, tighten with a torque of 25 Nm.
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