Checking and adjusting start of delivery of injection pump. — AUDI

Special tools and workshop equipment required

Adapter 2066

Counterhold 3036
Dial gauge

Note:

The start of delivery of the injection pump must always be re-adjusted:

After tensioning or removing and installing of the toothed belt;
After loosening the bolted connections on the injection pump or the camshaft sprockets.

Preconditions:

Toothed belt tension for camshaft OK

=> 5 cyl. Diesel Engine, Mechanical Components (2.4 l Engine); Repair group 13; Dismantling and assembling engine
5 cyl. Diesel Engine, Mechanical Components (2.4 l Engine)
Dismantling and assembling engine

Toothed belt tension for injection pump OK => page
23-10
.
Basic mechanical setting for engine OK => Page
23-13
.

Test sequence

Turn crankshaft to TDC of No. 1 cylinder -arrow-.
The -O- mark on the flywheel must be located under the edge of the inspection hole...

With the engine removed, rotate the crankshaft to TDC for cylinder 1 as follows:

Screw in TDC adjustment device 2068 A, as shown in the illustration.
Set adjustment device to 111.5 mm (the left notch on the vernier scale -arrow- is the reference point).
Rotate crankshaft until TDC mark "0" on flywheel aligns with edge of adjustment device...

...at the same time, the marks on the injection pump sprocket and the injection pump must align -arrows-.

Remove the toothed belt guard for injection pump drive.

Remove screw plug on the injection pump.
Screw in the dial gauge adapter 2066 in place of the screw plug (screw plug with sealing ring).
Screw the threaded side of the adapter plunger tightly into the dial gauge (small version, measuring range 0...3 mm).
Insert the dial gauge and plunger into adapter.
Preload the dial gauge to about 2 mm and tighten the adjusting nut on the adapter.

Rotate the crankshaft slowly against the direction of engine rotation -direction of arrow A-, until the pointer on the dial gauge no longer moves.
Set the measuring scale to "0".
Rotate the crankshaft slowly in direction of engine rotation -direction of arrow B-, until the mark -O- on the flywheel is aligned with the reference mark or the edge of the adjustment device.

Note:

TDC mark is to be approached by rotating crankshaft in direction of engine rotation. If you have accidentally passed the TDC mark:

Rotate the crankshaft in reverse direction until dial gauge reading is "0" again and re-approach TDC mark.

Read the start of delivery on the dial gauge:
Test value 0.93...1.07 mm/stroke

Notes:

If the test value is within the specified tolerance range, no re-adjustment is required.
If the test value is outside the tolerance range, the adjustment must be repeated. The adjustment value applies.

Adjusting

Loosen securing bolt of injection pump drive sprocket at camshaft by 1/2 turn using counterhold 3036 and ring socket tool V.A.G 1332/7.
Check again whether the crankshaft is positioned at TDC.
Using the counterhold 3036, rotate the drive sprocket slowly in -direction of arrow A-, until the pointer on the dial gauge no longer moves.
Set the measuring scale to "0".

Using the counterhold 3036, rotate the drive sprocket slowly in -direction of arrow B-, until the pointer on the dial gauge displays the following value:
Specified value: 1.00 ±0.02 mm stroke (start of delivery)

Hold the drive sprocket in this position using counterhold 3036 and tighten the securing bolt to approx. 50 Nm.
Re-check the start of delivery by rotating the crankshaft back and forth.

Notes:

Due to the slackness of the toothed belt, the indicated test value deviates from the specified value.
Example:

Specified value · 1.00 mm
Test value · - · 0.93 mm
Deviation · = · 0.07 mm /

Adding the deviation to the specified value yields the hold value for the second adjustment: 1.07 mm stroke.

Carry out the second adjustment as follows:

Loosen the securing bolt of the camshaft sprocket 1/2 turn.
Check again whether the crankshaft is positioned at TDC.
Using the counterhold 3036, rotate the drive sprocket slowly in the direction of arrow A - until the pointer on the dial gauge no longer moves.
Set the measuring scale to "0".
Using the counterhold 3036, rotate the drive sprocket slowly in the -direction of arrow B-, until the pointer on the dial gauge displays the hold value.

Example for hold value: 1.07 mm stroke

Hold the drive sprocket in this position using counterhold 3036 and tighten the securing bolt to approx. 50 Nm.
Re-check the start of delivery adjustment by rotating the crankshaft back and forth.
Specified value: 1.00 ±0.02 mm stroke

Note:

The adjustment must be repeated as often as necessary to obtain the specified value.

Tighten the drive sprocket securing bolt to final torque using counterhold 3036.

Note:

After a static adjustment of the injection pump, the injection lines on the injection pump must always be loosened and then re-tightened to 25 Nm. This relieves the strain on the pipes and prevents vibration fractures.

Remove the dial gauge and adapter.
Install the screw plug with a new sealing ring.
Install toothed belt guard.

Tightening torques

Component · Nm
Injection pump console to cylinder head · 50
Screw plug to injection pump 1) · 20
Drive sprocket for injection pump to camshaft · 100

1)
Replace sealing ring