The start of injection of the injection pump must be checked and adjusted after tightening, removing or replacing the toothed belt, as well as loosening the bolts of the injection pump or belt gears.
Examination
1. Set the crankshaft to the TDC position of the piston of the first cylinder, refer to subsection Setting the piston of the first cylinder to TDC.
2. Fix the camshaft using the adjusting ruler, refer to subsection Setting the piston of the first cylinder to TDC.
3. Now the VW-3359 rod should enter the hole in the hub of the gear wheel and the holder of the injection pump. Thus, the position of the injection pump is fixed. The rod must enter so that the hole (arrow on accompanying illustration) stood at a distance of approximately 3 mm in front of the pump hub.
Warning: Instead of the VW-3359 rod, you can use any rod G 6 mm, for example, a drill.
4. If the rod does not fit into the hole of the injection pump, despite the fact that the TDC marking and the position of the camshaft match, it is necessary to check the adjustment of the start of fuel injection again.
Injection start adjustment
5. Loosen the fastening bolts -1- of the injection pump gear wheel so that the toothed belt wheel can turn relative to the pump hub.
Warning: The central mounting bolt on the pump hub must not be loosened, otherwise the pump will move. After that, it will not be possible to adjust it at home.
6. Turn the injection pump hub so that the rod enters.
Attention: The rod must enter so that the hole (arrow illustration) stood at a distance of approximately 3 mm in front of the pump hub.
7. The rod must enter so that the hole (arrow illustration) stood at a distance of approximately 3 mm in front of the pump hub.
8. Take out the rod.
9. Remove the adjustment bar.
10. Rotate the crankshaft 2 revolutions in the direction of engine rotation and again set the No. 1 cylinder to TDC. Check the position of the markings on the flywheel and camshaft.
11. Fix the gear wheel of the injection pump with a pin. If the rod does not fit into the injection pump hole, repeat the adjustment process.
12. Take out the rod.
13. Install the cylinder head cover gasket. Fasten the cover, tightening torque 10 Nm.
14. Install the top timing belt cover.
15. Insert a plastic plug into the hole in the clutch cover.
Warning: In conclusion, check the dynamics of the start of injection of the injection pump (service station work).
Warning: After fine adjustment of the injection start point, it is necessary to tighten the 3 bolts securing the gear wheel of the injection pump to a torque of 20 Nm and then tighten it by 90° (1/4 turn). If the bolts were tightened in the specified way, after unscrewing them, they must be replaced with new ones.
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