This work is necessary, for example, when installing a toothed belt. A special adapter VW 2066 and a small "clock indicator", a measuring probe with a round dial with a measurement range of 0-3.0 mm (3) are used. A new sealing ring for the plug bolt on the fuel pump head (1) will also be needed. Adjusting the injection timing is a precise professional job that is only carried out in specialized workshops.
The timing belt tension must be set correctly.
Slide in the cold start assist rod.
Set the engine to the TDC position of the first cylinder.
Remove the timing belt cover.
Unscrew the plug bolt on the injection pump head in the middle of the high-pressure fuel lines.
Screw the adapter in place of the plug bolt.
Screw the adapter pusher to the clock indicator.
The hour indicator will adjust to approximately 2.5mm of pre-tension.
Using a small hammer, lightly tap the pump body to ensure that the centrifugal regulator returns to its normal position.
Slowly turn the crankshaft counterclockwise until the hour indicator pointer no longer moves.
Now set the dial indicator with a suitable pre-tension of 1 mm to "0".
Rotate the crankshaft clockwise until the VM mark is in line with the mark on the housing.
Read the indicator readings: the permissible range is from 0.83 to 0.97 mm of stroke on a 47 kW suction diesel engine or 0.73-0.87 mm of stroke on a 55 kW turbodiesel engine.
If this value is not reached, adjustment is necessary.
To do this, loosen both top bolts on the console and the retaining bolt on the outlet side of the pump on the stand.
Loosen the third fixing bolt on the fuel injection pump through one of the holes in the toothed belt wheel.
By rotating the high-pressure fuel pump around its axis, it is now possible to adjust the injection timing.
When adjusting the stroke value, it should be 0.90 mm on a 47 kW suction diesel engine and 0.80 mm on a 55 kW turbodiesel and should be set as accurately as possible (range ±0.02 mm). Then tighten the high-pressure fuel pump mounting bolts again to a torque of 25 Nm.
Remove the clock indicator with the adapter and replace the plug bolt with a new sealing ring with a torque of 15 Nm. If there are leaks, tighten with a torque of 25 Nm.
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