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Discussion Starter #1
What is the procedure for tuning the duse pump on WV Passat TDI after replacement. What should be the tolerance between the duse pump and the camshaft.
 

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Can you be more specific? What did you replace? Just the injectors? Did you also replace the injector holder bolts and camshaft or rocker bolts because they are critical stretch bolts and should not be reused.

Here is the what the manual says:
Using a caliper gauge (measuring range at least 400
mm), check dimension from outer edge of cylinder head
to round surface of pump-injector unit.

1 333.0 +/- 0.8 mm
2 245.0 +/- 0.8 mm
3 153.6 +/- 0.8 mm
4 65.6 +/- 0.8 mm

Place a dial gauge as shown onto adjustment screw of
Pump-Injector unit.
- Turn crankshaft in engine running direction until roller of
rocker lever is positioned on tip of cam lobe. Roller side -
arrow A - is positioned at highest point, dial gauge - arrow
B - is positioned at lowest point.
- Remove dial gauge.
- Turn adjustment screw in rocker lever until considerable
resistance is felt (Pump-Injector unit is on limit stop).
Turn adjustment screw 180 back from limit stop.
- Hold adjustment screw in this position and fasten lock nut
to 30 Nm.
 

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Discussion Starter #3
Can you be more specific? What did you replace? Just the injectors? Did you also replace the injector holder bolts and camshaft or rocker bolts because they are critical stretch bolts and should not be reused.

Here is the what the manual says:
Using a caliper gauge (measuring range at least 400
mm), check dimension from outer edge of cylinder head
to round surface of pump-injector unit.

1 333.0 +/- 0.8 mm
2 245.0 +/- 0.8 mm
3 153.6 +/- 0.8 mm
4 65.6 +/- 0.8 mm

Place a dial gauge as shown onto adjustment screw of
Pump-Injector unit.
- Turn crankshaft in engine running direction until roller of
rocker lever is positioned on tip of cam lobe. Roller side -
arrow A - is positioned at highest point, dial gauge - arrow
B - is positioned at lowest point.
- Remove dial gauge.
- Turn adjustment screw in rocker lever until considerable
resistance is felt (Pump-Injector unit is on limit stop).
Turn adjustment screw 180 back from limit stop.
- Hold adjustment screw in this position and fasten lock nut
to 30 Nm.
Thanks for the quick reponse chittychittybangbang. Sorry if some of the terms are confusing, we're not sure about some of the terminology.

We've replaced the camshaft, the roller bolts, rocker bolts and the duse pumps injectors. I don't know which is the procedure for tuning (how much mm should be between the camshaft and the duse pump roller bolts) the duse pump injectors.

Both duse pump injectors inject different ammount of fuel. We mesured them on dignostic tool, but we don't know which should be the right amount of fuel that should eb injected.

Can you post a picture, or draw some simple diagram?

regards
 

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Discussion Starter #4
this is the distance that we need.

the stuff that we added on the original picture are in red colour
 

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Just looking at that diagram, it's different from North American 4 cylinder TDI. For example, mine has a bearing on the injector rocker lever where it presses the injector top. At least on our pumpe duse, the distance "X" is not specified. You tighten the injector pressing screw until it's tight and then loosen it 180 degrees. Then you tighten the locking screw. This sets any play against the distance that you mention. This is just on the one I am familiar with.
 

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Discussion Starter #6
In which position should be the cramshaft whern we tightent the bolt? In position 1 or 2? (I thik it should be in position 1 but one guy si confused over here so he needs confirmation...) The duse pump is the same as with the american model.
Once again thanks chittychittybangbang
 

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