Servicing injection pump — VW

AGR ALH AQM ASV AYQ
Observe rules for cleanliness
=>Page
23-3
Removing and installing injection pump
=>Page
23-34
Dynamically checking and adjusting injection pump =>Page
23-42
Always renew seals and O-rings

Injection pump sprocket securing bolts
Take note of different types and torque settings =>Fig.
1

Injection pump sprocket
Two part
Take note of different types (Part No.) =>Fig.
1
Removing and installing => Page
23-34
, Removing and installing injection pump

Nut
For hub
Do not loosen. Otherwise the injection pump basic setting may be altered and this cannot be reset with normal workshop equipment

Seal
Renew

Pipe union, 25 Nm
For supply pipe
From fuel filter:

=> Repair Group 20; Removing and installing parts of fuel supply system; Servicing fuel filter
Direct injection and glow plug system with distributor pump
Removing and installing parts of fuel supply system
Servicing fuel filter

Injection pump
With quantity adjuster (metering)
With quantity adjuster (N146)
With modulating piston movement sender (G149)
With fuel temperature sender (G81)
Removing and installing
=>Page
23-34
Dynamically checking and adjusting commencement of injection
=>Page
23-42

Fuel shut-off valve (N109), 40 nm
Checking =>Page
01-64
, final control diagnosis

Pipe union
For return pipe

Return pipe
To fuel filter control valve:

=> Repair Group 20; Removing and installing parts of fuel supply system; Servicing fuel filter
Direct injection and glow plug system with distributor pump
Removing and installing parts of fuel supply system
Servicing fuel filter

25 Nm
Injector pipes
Tighten to 25 Nm
Remove with ring spanner 3035
Always remove pipework complete
Do not alter shape

Pipe union, 45 Nm
With pressure valve

Injector
Removing and installing
=> Page
23-48
Checking => Page
23-51
For 3rd cylinder with needle lift sender (G80)
Checking needle lift sender
=> Page
23-86

20 Nm
Retainer
Mounting
Heat insulation seal
Renew

10 Nm
Commencement of injection valve (N108)
Checking =>Page
01-64
, final control diagnosis

O-Ring
Renew

Strainer
Clean strainer if soiled

Timing control cover
If leaking, replace O-ring =>Page
23-53

Sleeve
With securing nut

Compact bracket
Removing and installing:

=> Repair group 13; Dismantling and assembling engine
Direct injection and glow plug system with distributor pump
Dismantling and assembling engine

Fig.1
Types of injection pump sprocket securing bolts

Version -A-:

Securing bolts with chamfer on shaft and pointed end -arrows-

Part number on injection pump sprocket:
038 130 111 A
Torque setting of securing bolts:
20 Nm + 1/4 turn (90°)
Renew securing bolts

Note:

The securing bolt -A- is a stretch bolt and must always be replaced.

Version -B-: Securing bolts without chamfer on shaft and without pointed end

Part number on injection pump sprocket:
038 130 111 B
Torque setting of securing bolts:
25 Nm
Securing bolts need not be renewed