Diesel engine high pressure fuel pump
- 1 - bolt, 20 Nm + tighten by 90°. New bolts must be used during installation;
- 2 - fuel pump pulley;
- 3 - nut;
- 4 - connecting nipple, 25 Nm. For the fuel supply hose from the fuel filter;
- 5 - high pressure fuel pump;
- 6 - fuel cut-off valve, 40 Nm;
- 7 - connecting nipples. For the supply pipeline;
- 8 - feed pipe. To the fuel filter;
- 9 - nut, 25 Nm;
- 10 - high pressure fuel lines, 25 Nm. Replacement of lines must be done only as a set. Do not bend the lines;
- 11 - connecting nipple, 45 Nm. With pressure valve;
- 12 - bolt, 25 Nm;
- 13 - fuel injector. The fuel injector contains a needle movement sensor;
- 14 - bolt, 20 Nm;
- 15 - clamp;
- 16 - bracket;
- 17 - Thermal seal. A new thermal seal must be used during installation;
- 18 - bolt, 10 Nm;
- 19 - injection start valve;
- 20 - mesh filter;
- 21 - O-ring of circular cross-section. A new O-ring must be used during installation;
- 22 - bolt, 25 Nm;
- 23 - fuel injection timing advance clutch cover;
- 24 - bushing with nut;
- 25 - console;
- 26 - bolt, 25 Nm
Location of vacuum hoses on a TDI diesel engine
- 1 - exhaust gas recirculation valve;
- 2 - to the vacuum tank for regulating the boost pressure.
- In the turbocharger:
- 3 - to the vacuum tank for the intake manifold valve;
- 4 - switching valve for intake manifold valve;
- 5 - to the T-connector;
- 6 - exhaust gas recirculation control valve;
- 7 - T-connector;
- 8 - magnetic valve for limiting boost pressure;
- 9 - valve;
- 10 - from the brake booster;
- 11 - air filter;
- 12 - valve;
- 13 - vacuum pump
The fuel injection timing should be checked with the engine running using an electronic tester. Since electronic testers are only available at service stations, the fuel injection timing adjustment using a mandrel is provided below, but this method can only approximately set the fuel injection timing, so it is necessary to adjust the fuel injection timing at a service station as soon as possible. Fuel injection timing adjustment should be performed after replacing the timing belt, replacing the high-pressure fuel pump or timing belt pulleys.
Examination
1. Turn the engine crankshaft to a position where the piston of the first cylinder is at top dead center in the compression stroke.
2. In this position, fix the camshaft with an adjusting ruler. In this position, insert the VW-3359 mandrel into the hole of the fuel pump pulley mounting flange and the hole of the fuel pump bracket (shown by arrow). The mandrel will prevent the fuel pump pulley from turning. Insert the mandrel to such a depth that the hole in the mandrel is located at a distance of about 3 mm from the mounting flange of the fuel pump pulley. A 6 mm drill shank can be used as a mandrel.
3. If the hole in the mounting flange of the fuel pump pulley and the fuel pump bracket are not aligned and the mandrel cannot be installed, it is necessary to perform the initial setting of the fuel injection timing.
Initial adjustment of fuel injection timing
1. Loosen the fuel pump pulley mounting bolts (1) so that the pulley can rotate relative to the mounting flange. Do not unscrew the central mounting flange mounting bolt.
2. Rotate the fuel pump pulley mounting flange until the mounting holes in the flange and the fuel pump bracket are aligned. Insert the mandrel into the aligned holes and secure the mounting flange from turning.
3. Tighten the fuel pump pulley mounting bolts to 20 Nm.
4. Remove the mandrel that secures the fuel pump pulley. Remove the adjusting ruler that secures the camshaft from turning.
5. Turn the engine crankshaft two full revolutions in the direction of engine rotation and set it to a position where the piston of the first cylinder is at the top dead center in the compression stroke. Check that the timing mark on the flywheel is aligned with the pointer.
6. Using a 6mm diameter mandrel, secure the fuel pump pulley from turning. If the mandrel cannot be installed, repeat the adjustment process.
7. Remove the mandrel from the fuel pump pulley.
8. Install the cylinder head cover gasket, cylinder head cover and secure with nuts, tightening them to a torque of 10 Nm.
9. Install the upper timing belt cover.
10. Install a plastic plug into the hole in the clutch housing.
11. Have the fuel pump injection timing checked and adjusted at a service station as soon as possible.
12. After fine-tuning the fuel pump injection timing, tighten the three fuel pump pulley mounting bolts to 20 Nm and then turn them through an angle of 90°. After tightening the bolts in this manner, they must be replaced each time they are loosened.
Visitor comments