Diesel High Pressure Fuel Pump
- 1 - bolt, 20 Nm + tighten by 90°. At installation it is necessary to use new bolts;
- 2 - fuel pump pulley;
- 3 - nut;
- 4 - connecting fitting, 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 fittings. For the supply pipeline;
- 8 - supply pipeline. To the fuel filter;
- 9 - nut, 25 Nm;
- 10 - high pressure fuel lines, 25 Nm. Pipelines must only be replaced as a set. Do not bend pipelines;
- 11 - connecting fitting, 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. When installing, a new thermal seal must be used;
- 18 - bolt, 10 Nm;
- 19 - injection start valve;
- 20 - mesh filter;
- 21 - O-ring. At installation it is necessary to use a new sealing ring;
- 22 - bolt, 25 Nm;
- 23 - cover for the fuel injection advance clutch;
- 24 - sleeve with nut;
- 25 - console;
- 26 - bolt, 25 Nm
Location of the vacuum hoses on the TDI diesel engine
- 1 - valve of the exhaust gas recirculation system;
- 2 - to the vacuum tank for adjusting the boost pressure.
- In the turbocharger:
- 3 - to the vacuum tank for the intake manifold valve;
- 4 - switching valve for the intake manifold valve;
- 5 - to the T-shaped connector;
- 6 - exhaust gas recirculation control valve;
- 7 - T-shaped connector;
- 8 - magnetic valve for limiting boost pressure;
- 9 - valve;
- 10 - from the vacuum brake booster;
- 11 - air filter;
- 12 - valve;
- 13 - vacuum pump
The fuel injection timing must be checked with the engine running using an electronic tester. Due to the fact that electronic testers are available only at service stations, the following is the adjustment of the fuel injection timing using a mandrel, but this method can only determine approximately the fuel injection timing, so it is necessary to adjust the fuel injection timing at the service station as soon as possible. The fuel injection timing must be adjusted after replacing the toothed belt, replacing the high pressure fuel pump or the toothed belt pulleys.
Examination
1. Turn the crankshaft of the engine in such a position that the piston of the first cylinder is at top dead center on 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). Dorn will fix the fuel pump pulley from turning. Insert the mandrel to such a depth that the hole in the mandrel is about 3 mm from the fuel pump pulley mounting flange. A drill shank with a diameter of 6 mm 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 make the initial setting of the fuel injection timing.
Initial adjustment of the fuel injection timing
1. Loosen the mounting bolts (1) pulley of the fuel pump, as a result of which the pulley can rotate in relation to the mounting flange. Do not unscrew the center mounting flange bolt.
2. Rotate the fuel pump pulley mounting flange until the mounting holes in the flange and fuel pump bracket are aligned. Insert a mandrel into the aligned holes and secure the mounting flange from turning.
3. Tighten the fuel pump pulley bolts to 20 Nm.
4. Remove the mandrel that secures the fuel pump pulley. Remove the adjusting ruler that fixes 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 No. 1 cylinder piston is at top dead center on the compression stroke. Check that the alignment mark on the flywheel is aligned with the pointer.
6. Using a mandrel with a diameter of 6 mm, fix 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 10 Nm.
9. Establish the top casing of a gear belt.
10. Install the plastic plug in 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 adjustment of the injection timing of the fuel pump, tighten the three bolts securing the fuel pump pulley to a torque of 20 Nm and then tighten them by an angle of 90°. Once the bolts have been tightened in this way, they must be changed each time they are unscrewed.
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