Attention: For a 90 hp engine. supercharged after the static adjustment described here, the start of delivery must be adjusted dynamically, i.e. with the engine running (workshop operation, as this requires an electronic device). The 110 hp engine has with supercharging, the feed start can only be adjusted dynamically.
Notes for 75 hp engine. since 10/94 (AAZ) are given at the end of the section.
Prerequisites for verification:
- The toothed belt is tensioned, the engine control is correctly adjusted, see «Timing belt installation».
- The engine cold start accelerator rod is fully retracted.
Examination
Turn the crankshaft to TDC position for cylinder 1. Turn the crankshaft until the TDC mark on the flywheel and the clutch housing boss, and the mark on the gear wheel of the injection pump and the bracket, are aligned. Cm. «Engine control adjustment».
Unscrew and remove the screw plug in the injection pump.
Screw in adapter instead of screw plug (V.A.G-2066) and pointer indicator (measuring range from 0 to Zmm), until the indicator hand begins to move. Set the indication on the indicator scale «ABOUT». Then press the dial indicator further until the arrow shows a value of 2.5 mm.
Attention: for cars with 7/92 for the dial indicator, you must use the adapter 3313 (modified cork thread M10x1).
Using an interchangeable socket SW19, slowly turn the crankshaft against the direction of rotation (arrow A) until the indicator needle stops moving.
Set the value on the dial indicator scale «0».
Turn the engine crankshaft in the direction of rotation (clockwise, arrow -B-), until the TDC mark on the flywheel matches the timing mark. Now the indicator should show the control value.
The ratio of engine designations and their parameters see at the beginning of the Guide.
Caution: If the control value is within the specified tolerance, no further adjustment is required. If a new adjustment is to be carried out, the adjustment value must be set.
To adjust, loosen 3 bolts -2- fastening the injection pump to the console and bolt -1- fastening to the rear support.
Loosen the lower and right bolts of fastening to the console from the front through the hole in the gear wheel of the injection pump (arrow).
Check if the crankshaft is at TDC for cylinder 1, set it to TDC if necessary.
Set the prescribed value for the start of fuel delivery by turning the injection pump.
Attention: If when turning the injection pump there is a noticeable tension in the high pressure fuel lines, then it is necessary to loosen the union nuts of the high pressure fuel lines.
Tighten the injection pump mounting bolts to 25 Nm.
Check again the beginning of the fuel supply by turning the crankshaft back and forth.
If loosened, tighten union nuts for high pressure fuel lines to 25 Nm.
Remove the dial indicator and screw the screw plug into the injection pump cover with a torque of 15 Nm. If a leak is detected, tighten the plug with a torque of 25 Nm, no more.
Attention: Replace the sealing ring of the screw plug with a new one every time.
Install the upper toothed belt cover.
75 hp engine since 10/94 (AAZ)
The start of fuel delivery is checked and adjusted with the lock pin 3359 inserted into the gear wheel, when the engine crankshaft is in the TDC position for cylinder 1, see section above «Timing belt installation».
If the locking pin does not insert, lock the camshaft, loosen the camshaft and injection pump gears, and rotate the hub of the injection pump gear to a position where the pin can lock it.
Check again if the crankshaft is at TDC for cylinder 1 and tighten the camshaft and injection pump gears, see above.
Turn crankshaft 2 turns in direction of rotation and set cylinder 1 to TDC again. Secure injection pump sprocket with locking pin. If this is not possible, then loosen the fastening bolts and turn the hub of the gear wheel of the injection pump to a position in which the pin can fix it. In this position, tighten the injection pump sprocket bolts to 25 Nm.
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