Application: Before starting work, read the warnings in paragraph 1. Prior to initial injection timing, a dial gauge and a suitable adapter are required.
Withdrawal
1. Disconnect the negative cable from the battery as described in chapter 5A, move it away from the output.
2. Turn away nuts and remove a plastic cover from above the engine.
3. Remove the top timing belt cover.
4. Remove the valve cover - see chapter 2B.
5. Set the piston of the first cylinder to the TDC of the compression stroke, as described in chapter 2B. To perform this procedure, you will need a camshaft locking bar.
6. Turn away bolts of connections and remove fuel lines from TNVD. Pay attention to the fact that a non-return valve is built into the bolt connection to the return line (pic. 6.6). Remove sealing washers.
7. Hang tags on the wiring connectors, disconnect it from the injection pump.
8. Unscrew the connecting nuts of the fuel pipes to the injectors and injection pump and remove them as a set (pic. 6.8). When unscrewing the injection pump fittings, hold with an open-end wrench. Try not to bend the tubes.
9. Plug the openings of the tubes, nozzles of the injection pump fittings from the penetration of dirt.
10. Remove the timing belt tensioner as described in chapter 2B.
11. Attach a suitable tool to the injection pump sprocket to hold it (pic. 6.11).
12. Turn away a nut of fastening of an asterisk of TNVD on one turn.
13. Using a suitable puller, remove the sprocket from the injection pump shaft (pic. 6.13). When using a puller, do not apply too much force or knock on the shaft to avoid damaging the pump.
14. Turn away a nut completely and remove an asterisk. Remove the key from the slot on the shaft (pic. 6.14).
15. Mark the location of the pump on the bracket for ease of installation. Remove the front bolts securing the pump to the mounting bracket. Access to the two internal bolts is possible from the front of the rear cover of the injection pump. Access to one more bolt is possible from the injection pump side of the mounting bracket.
16. Turn away a back bolt of fastening and remove the pump from an arm of fastening (pic. 6.16).
Installation and adjustment
17. Install the pump on the bracket and tighten the rear mounting bolt. Tighten the bolt and flare nut to the specified torque to center the pump.
18. Turn the pump to center it on the oblong holes in the front of the bracket, install the front mounting bolts and tighten them at this stage "by hand". If a previous pump is being installed, align the pre-marked marks and tighten the mounting bolts.
19. Insert a key into the slot on the pump shaft, put on an asterisk and tighten the nut. While holding the sprocket stationary with the tool used to loosen it, tighten the nut to the specified torque.
20. Align the holes designed to install the pump in the position corresponding to the TDC of the compression stroke of the first cylinder and insert the fixing pin into them.
21. Install the timing belt and tensioner as described in chapter 2B.
22. Before connecting the wiring and fuel pipes, make the following adjustments.
23. Make sure that all TDC marks are aligned, remove the camshaft retaining plate and the pin from the injection pump sprocket.
24. Unscrew the plug at the rear of the injection pump, remove the sealing washer and screw in the adapter (adapter) with indicator head (pic. 6.24).
25. Raise the indicator by 2 mm and slowly turn the crankshaft counterclockwise until the indicator arrow stops. Cock the indicator by 1 mm. reset the scale.
26. Slowly turn the engine clockwise until the mark on the flywheel/faceplate aligns with the pointer on the bell cutout. Further, do not rotate the crankshaft - the indication may go astray and the procedure will have to be repeated.
27. Indicator reading (plunger lift) in this position (initial injection advance) should be 0.7±0.2 mm.
28. If adjustment is required, loosen the pump mounting bolts one turn and rotate it until the desired reading is reached.
29. Tighten the pump mounting bolts to the specified torque, repeat the procedure and verify that the indicator is accurate.
30. Remove the indicator, wrap and tighten the plug with a new seal.
31. Install the fuel pipes between the injectors and the pump and tighten their nuts to the prescribed torque.
32. Connect the electrical wiring connectors to the pump.
33. Install the fuel lines by screwing in the connection bolts with new sealing washers and tighten them to the prescribed torque. Bolt with non-return valve - from the return line.
34. Install the valve cover as described in chapter 2B. Install the outer timing belt cover.
35. Connect the battery as described in chapter 5A.
36. Now the injection pump must be pumped with a hand pump. To drain the fuel from the injection pump, the Audi vacuum pump has a built-in container. Connect the pump to the injection pump return fitting and pump until bubbles stop coming out of the pump. Do not allow fuel to enter the vacuum pump.
37. Connect the return line to the pump, start the engine and check for leaks.
38. Now you need to check the dynamic injection advance. This requires specialized diagnostic equipment. Contact your dealer for help.
39. When you're done adjusting, always loosen the fuel pipe nuts and retighten them to relieve stress that could cause them to break with constant vibration.
40. Install the top plastic engine cover.
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