Injection pump, servicing: Notes

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Only vehicles with engine code ALH

Note rules of cleanliness. Refer to Rules of cleanliness
Always replace sealing rings and O-rings

Fig 1: Exploded View Of Injection Pump Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Seal

Always replace

2 - Connecting piece 25 Nm

For supply line
From fuel filter

3 - Injection pump

With quantity adjuster
With Fuel Temperature Sensor -G81-*, checking. Refer to Fuel Temperature Sensor, checking
With Quantity Adjuster -N146-*, checking. Refer to Modulating Piston Displacement Sensor and quantity adjuster, checking
With Modulating Piston Displacement Sensor -G149-*, checking. Refer to Modulating Piston Displacement Sensor and quantity adjuster, checking

4 - Fuel Cut-off Valve -N109-, 25 Nm

5 - Connecting piece

For return line

6 - Return line

To regulator valve/fuel filter

7 - 25 Nm

8 - Injection lines

Tighten to 25 Nm
Use 3035 ring spanner to remove and install
Always replace two-piece wiring set completely
Do not change bend shape

9 - Connecting piece, 45 Nm

With pressure valve

10 - 25 Nm

11 - Fuel injector

Removing and installing. Refer to Injectors, removing and installing
Checking. Refer to Injectors, checking
For cylinder 3 with needle lift sensor
Check Needle Lift Sensor -G80-*. Refer to Needle lift sensor, checking

12 - 20 Nm

13 - Tension bracket

14 - Mounting bracket

15 - Copper washer

Always replace

16 - 10 Nm

17 - Cold Start Injector -N108-*

Checking. Refer to Cold Start Injector, checking

18 - Gasket

Always replace

19 - Sieve

Clean strainer if dirty

20 - Timing control cover

Replace seal if leaking.

21 - Socket

With nut

22 - Bracket

23 - 25 Nm

24 - Securing bolts of injection pump sprocket

Note different versions and tightening torques. See Versions of securing bolts for injection pump sprocket

25 - Injection pump sprocket

Note different versions (replacement part numbers). See Versions of securing bolts for injection pump sprocket

26 - Mounting nuts

For hub
Must not be loosened under any circumstances. Basic setting of the injection pump may be altered, this cannot be reset with normal workshop equipment