Renewing pump cover throttle lever bush, pump cover gasket and throttle lever shaft O-ring — VW

1X
Note:

The items given which are not pictured refer to the blow-up diagram X23-0217, Page
23-49
.

Special tools, testers and auxiliary items

Thrust plate VW 401
Thrust plate VW 454
Drift 10-206

Note:

The smallest mal-adjustment of the fuel delivery adjusting screw can cause sooting or loss of engine power. Therefore it is important that the adjusting screw is re-installed in the same position. On no account may the fuel delivery adjusting screw be screwed in past the original position.

Work sequence

Remove return spring and lower throttle lever
=>Page
23-54
.

Mark position of fuel delivery adjusting screw relative to pump cover, e.g. slot of screw relative to pump cover -arrows-.
Loosen locking nut against the locking sleeve and unscrew fuel delivery adjusting screw from the pump cover.
Remove injection pipes with slotted ring spanner 3035.
Remove fuel return pipe.
Wrap a cloth around the fuel pump to absorb leaking fuel.
Remove cover securing bolts (Qty. 4).
Separate the idling speed throttle lever -12- from the idling speed adjusting rod -3- by removing the circlip -5-.
Tip pump cover -31- slightly to one side, and detach idling speed spring -28- (e.g. using locally manufactured hook). Do not over tension spring.

Lift pump cover slightly, press throttle lever shaft -24- towards the inside of the cover (e.g. with a screwdriver handle) whilst taking the cover off.
Remove pump cover and press bush -29- out as illustrated.
Clean pump cover

Note:

Various bushes are available depending on type of pump. Select correct bush by comparing with old bush.

Coat new bush outer diameter with D6 and press into the cover up to the collar as illustrated.
Carefully remove surplus D6.

Install new throttle shaft O-ring -2-.
Ensure that the thrust washer -3- is in place.
Fit new pump gasket. (Small protrusions on gasket outer edge prevent the gasket falling out when the cover is fitted).
Moisten throttle lever shaft and O-ring with Diesel land press into bush, then fit pump cover.
Attach idling speed spring.
Secure pump cover.
Install fuel delivery adjusting screw with new O-ring, as marked.
Install return spring and throttle lever
=>Page
23-54
.
Run engine until warm and check idling speed and engine governed speed.
Check exhaust opacity with combustion tester V.A.G 1500

=> Fault finding programme Diesel engine No. 2 "excessive black exhaust smoke".