Piston stroke test and adjustment values
Engine | 1X, DAV | ABL |
Test value: piston stroke, mm | 0,93 – 1,07 | 0,85 – 0,95 |
Adjustment value piston stroke, mm | 1,00 ± 0,02 | 0,90 ± 0,02 |
1. Set 1 cylinder to TDC. To do this, turn the crankshaft so that the TDC mark on the flywheel and the influx of the clutch housing, as well as the mark on the injection pump gear and the console, coincide (see subsection 2.5.2).
2. Do not pull out the cold start accelerator control cable.
3. Timing belt tension should be correct.
5 cylinder engine
4. Remove the lower engine compartment mudguard.
5. Tilt the radiator together with the lock support forward.
6. Remove the injection pump timing belt cover.
7. Unscrew the screw plug on the injection pump cover.
8. Screw in an adapter instead of a cork (V.A.G-2066) with small watch micrometer (measuring range 0–3.0 mm) until the micrometer needle begins to move. Set the micrometer by the adjusting ring to "0". Then press the micrometer further: the reading on the scale is approximately 2.5 mm (5-cylinder engine: 2.0mm).
9. Turn the crankshaft gradually in the opposite direction to the engine rotation (counterclock-wise) until the micrometer needle stops moving.
10. Set the micrometer with a reading of about 1 mm to "0". 11. Rotate the crankshaft in the direction of engine rotation (clockwise) until the TDC mark on the flywheel matches the corresponding mark. Now the micrometer should show the test value (see table. Piston stroke test and adjustment values).
Attention! If the test pressure is within the allowable limits, no new adjustment is required. If a new adjustment is to be made, the adjustment value must be set.
12. To adjust, unscrew the three screws (2) on the console and mounting bolt (1) back stop.
13. By rotating the injection pump, set the adjustment value of the piston stroke and tighten the fastening bolt to 25 Nm.
14. Remove the micrometer and screw the screw plug into the pump cover.
Attention! Always replace the sealing ring of the screw cap. Tightening torque - 15 Nm. In case of depressurization, it is allowed to tighten with a torque of no more than 25 Nm.
Adjustment
Adjustment of the 4-cylinder engine
1. Bolts on the console; 2. Back gauge bolts
Adjustment of the 5-cylinder engine
The adjustment can be made as follows:
- rotation of the injection pump after unscrewing the bolts of the console and stop of the 4-cylinder engine (first way);
- rotation of the injection pump drive gear (second way).
Attention! In order to be able to observe the readings of the micrometer when the drive wheel of the high-pressure fuel pump is rotated, rotate from below the machine installed on the gantry or lift.
First way
1. Loosen the bolt 1 turn while holding the injection pump drive gear with a counterholder.
2. Check the position of the crankshaft at TDC, if necessary, set it to TDC.
3. Turn the injection pump drive gear with a counterstop against the direction of engine rotation (in the direction of arrow A), until the micrometer needle stops moving.
4. Set the micrometer to "0".
5. Turn the injection pump drive gear with a counterhold in the direction of engine rotation (in the direction of arrow B), until the micrometer shows the adjustment value (start of filing).
6. Hold the drive gear in this position with a counterhold and tighten the fastening bolt first to approx. 50 Nm.
7. Once again check the beginning of the feed by rotating the crankshaft back and forth. Then check the beginning of the feed again.
Attention! As a result of slipping of the toothed belt, the test value deviates slightly from the adjusted value.
Example:
Adjusted value (required value) | = 1.00 mm stroke |
Test value | = 0.93 mm stroke |
Deviation (1.00 minus 0.93) | = 0.07 mm stroke |
Deviation Desired value gives leading control value (for the second adjustment) | = 1.07 mm stroke |
Second way
1. Loosen the bolt 1 turn while holding the injection pump drive gear with a counterstop.
2. Check the position of the crankshaft at TDC, if necessary, set it to TDC.
3. Turn the drive gear of the injection pump with a counterhold against the direction of engine rotation (in the direction of arrow A), until the micrometer needle stops moving.
4. Set the micrometer to "0".
5. Turn the injection pump drive gear with a counterhold in the direction of engine rotation (in the direction of arrow B), until the micrometer shows the adjustment value (in the given example - 1.07 mm).
6. While holding the injection pump drive gear in this position, use a counterholder to pre-tighten the fastening bolt to a torque of about 50 Nm.
7. Check again the beginning of the feed by rotating the crankshaft back and forth.
Attention! If necessary, repeat the adjustment as many times as necessary until the required value is reached.
8. While holding the injection pump drive gear with a counterholder, tighten it to 100 Nm.
9. Remove the micrometer and tighten the screw plug on the pump cover.
Attention! The sealing ring of the screw plug must always be replaced. Tightening torque: 25 Nm.
10. Install the toothed belt guard with lock support and the lower engine compartment mudguard.
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