Removing and installing injection pump cover: Audi 2.4 D (AAS)

Special tools and workshop equipment required

Ring spanner 3035

Removing

Remove the adjustment lever with load impact damping => Page
23-58
.
Mark the position of the fuel quantity adjustment screw relative to the pump cover, e.g. screw slot to pump cover -arrows-.

Notes:

Even minor changes of the fuel quantity adjustment screw position may lead to smoke development or performance loss of the engine. For this reason it is important to obtain the identical position upon re-installation. Under no circumstances must the fuel quantity adjustment screw be turned beyond the initial position.
The fuel quantity adjustment screw is secured by a plastic sleeve. To turn the fuel quantity adjustment screw the plastic sleeve must be destroyed.

Loosen lock nut, turn against the securing sleeve and unscrew the fuel quantity adjustment screw from the pump cover.

Disconnect the injector pipes using open ring spanner 3035.

Note:

Always remove complete pipe set. Do not alter pipe shape.

Detach the connector for the idling speed increase actuator -1-.
Unscrew the idling speed increase actuator retainer.
Place a cloth around the injection pump housing to catch escaping fuel.
Unscrew the fuel return line on the injection pump and lay it aside.

Note:

Close off the line with a clean closure plug.

Loosen the residual fuel quantity adjuster screw lock nut and turn the residual fuel quantity adjuster screw outwards.
Unscrew the cover securing bolts.

Tilt the injection pump cover slightly to the side, disengage the idling speed tension spring -arrow- (e.g. using a wire hook fashioned for this purpose). Do not over-stretch the spring in the process.

Slightly lift up injection pump cover, push adjustment lever shaft -arrow- towards inside of cover while removing cover (e.g. using screwdriver handle).

Installing

Installation is carried out in the reverse order; note the following:

Note:

If radial play of the adjustment lever within the injection pump cover bearing bush can clearly be felt, the adjustment lever bearing bush in the pump cover must be replaced => Page
23-69
.

Replace O-ring -2-, coat O-ring and adjustment lever -1- with diesel fuel.
Before setting injection pump cover in place, check again whether the thrust washer -3- is fitted on the adjustment lever shaft.
Set injection pump cover in place with new gasket, insert adjustment lever into bearing bush in the process.

Engage the idling speed tension spring -arrow- (e.g. using a wire hook fashioned for this purpose). Do not over-stretch the spring in the process.
Tighten pump cover.

Insert fuel quantity adjustment screw using new O-ring=>Page
23-74
and turn in until the lock nut is in contact with the pump cover.
Install return spring and adjuster lever shaft with load impact damping =>Page
23-60
.
Let engine run warm.
Adjust basic setting of residual fuel quantity
=>Page
23-33
.
Check idling speed and cutoff speed and adjust as necessary => Page
23-28
Check exhaust gas opacity using V.A.G 1500 combustion tester:

=> Maintenance Manual

Tightening torque

Component · Nm
Pump cover to pump · 10