Service

Golf 1992 , Vento 1992 ➤

Diesel Injection and Glow Plug System
Engine ID AAZ 1Y

Edition 10.1991

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System

Repair Group
01 - Self diagnosis
23 - Mixture preparation, Injection
28 - Glow plug system

Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

Contents

01 - Self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Technical data of self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Connecting fault reader V.A.G 1551 and selecting engine electronics control unit . . . . . . . .1
1.5 Interrogating fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.6 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.7 Erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.8 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.9 Reading measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1 Servicing fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.1 Servicing fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.2 Injection pump with two-part sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.3 Injection pump with two-part sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.4 Servicing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.6 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.7 Actuator controlled, load-dependent injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
1.8 Removing and installing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
1.9 Checking and adjusting injection pump timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
1.10 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.11 Adjusting idling speed, idling speed boost and engine governed speed . . . . . . . . . . . . . . . .34
1.12 Load change speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1.13 Residual volume basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
1.14 Idling speed boost actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1.15 Checking commencement of injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1.16 Checking engine temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.17 Resistance figures for engine temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.18 Checking idling speed boost valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.19 Check full load stop valve, engine 1Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.20 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
1.21 Servicing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
1.22 Checking injector nozzle valve tip for damage, injection pressure and for leakage. . . . . . .43
2 Servicing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2.1 Servicing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2.2 Removing and installing throttle lever or return spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
2.3 Renewing pump cover throttle lever bush, pump cover gasket and throttle lever shaft O-ring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.4 Renewing fuel delivery adjusting screw O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
2.5 Renewing idling speed boost shaft O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
2.6 Renewing injection timing device cover O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.7 Renewing CSA lever/cover O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.8 Sealing injection pump connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
1.2 Checking glow plug current consumption with V.A.G 1315A . . . . . . . . . . . . . . . . . . . . . . . .60
1.3 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
1.4 Glow plugs with burned electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Contents i
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

ii Contents
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

01 - Self diagnosis

1 - Self diagnosis
1.1 - Self diagnosis

1.2 - Function

The control unit (J179) for the automatic glow period is equipped with a fault memory.

If faults occur in the sensors and components being monitored, they will be stored in the fault memory together
with an indication of the type of fault.

The stored faults are output after initiating the fault display => Page 3 .

This fault memory must be erased once the faults have been eliminated => Page 6 .

Faults which can be attributed to a temporary open circuit in the wiring or a loose contact, will also be stored.
These faults will be displayed as sporadic faults "SP".

1.3 - Technical data of self diagnosis

Equipped with

◆ Fault memory: Non-volatile memory and volatile memory

◆ Rapid data transfer

Selectable functions

Function Ignition switched Engine idling

on
02 Interrogate fault x x
memory
03 Final control di‐ x x
agnosis
05 Erase fault mem‐ x x
ory
06 End output x x
08 Read measured x x
value block

1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit

Special tools, testers and auxiliary items

◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3

1.1 - Self diagnosis 1

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Note:
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.
Test conditions

• Battery voltage OK.

• Fuse 21 OK.
• Earth connections on engine and gearbox OK.

Work sequence

- -> Unclip cover for diagnostic connections.

- Connect fault reader V.A.G 1551 with cable V.A.G 1551/3.

-> Indicated on display:

V.A.G - SELF DIAGNOSIS HELP
1 - Rapid data transfer*
2 - Flash code output*

* Appears alternately

Note:
If the display remains blank:
=> Fault reader operating instructions

- Depending upon desired function:

Switch on ignition
or
Start engine.
- Operate fault reader taking into account the information on the display:
- Input 1 for "Rapid data transfer".
- Input 41 for address word "Diesel pump electronics" and confirm with Q key.

-> The fault reader V.A.G 1551 display will show the control unit identification, e.g.:
028906124B Turbo Diesel V02
Coding 00127 WSC0000

◆ 028906124B = Part No. of the control unit (for up-to-date control unit versions see parts catalogue)
◆ Turbo diesel = engine version
◆ D40 = Control unit software version
◆ Coding: 127 without air conditioner, 124 with air conditioner

◆ WSC...Dealership number of the V.A.G dealer

- Press ⇒ key.

-> Indicated on display:

2 01 - Self diagnosis
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

Rapid data transfer HELP

Select function XX

- Further measures see repair procedures.

1.5 - Interrogating fault memory

Special tools, testers and auxiliary items

◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3

Note:

The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.

Work sequence

- Connect fault reader V.A.G 1551 and select Diesel pump electronics control unit (address word 41); selection
is carried out with engine idling => Page 1

Only when engine does not start:

- Switch on ignition.

- Switch on printer with the Print button

(Warning lamp in button lights up).

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Input 02 for "Interrogate fault memory" function and confirm with Q.

-> The number of faults stored or "No fault recognised!" will be shown on the display.
X Faults recognised!

Note:

If something different is indicated on the display:

=> Fault reader operating instructions

If one or more faults are stored:

The faults stored will be displayed and printed out one after the other.
Then the display will show:

If no fault is stored:

- Press ⇒ key.

- Input 06 for "End output" function and confirm with Q.

- Locate and eliminate faults printed out as per fault table => Page 4 .
- Erasing fault memory => Page 6

1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit 3
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.6 - Fault table

Notes:

◆ The fault tables on the following pages are listed according to the 5- digit fault code on the left.
◆ Before renewing components indicated as being faulty, check the wiring and connectors to these compo‐
nents as well as the earth connections using current flow diagram. This is particularly relevant if faults are
output as "occurring sporadically" (SP).

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00626
Glow period warning lamp -
K29
Short to positive Wiring short to positive Warning lamp does not - Check K29, => Page
Warning lamp defective light during glow period 6 , final control diagno‐
sis
01050
Glow plug monitor
Open circuit/short to Wiring short to earth Poor cold starting - If necessary replace fuse.
earth Wiring open circuit Warning lamp -K29- flash‐ If necessary replace glow
Fuse -S39- defective es plugs
Short to positive Wiring short to positive - Check wiring and con‐
Relay does not switch off nections according to cur‐
rent flow diagram.

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01167
Full throttle stop valve -N194
Open circuit/ Wiring short to positive slightly reduced power at - Check N195, => Page
short to positive Wiring open circuit to altitude 6 , final control diagno‐
valve sis
Valve defective
Short to earth Wiring short to earth Black smoke at altitudes
Valve defective above 1000 m above sea
level
01168
Idling speed boost valve -
N177
Short to positive Wiring short to positive Idling speed too low with - Check N177, => Page
Valve defective cold engine 6 , final control diagno‐
sis
Open circuit/short to Wiring short to earth
earth Wiring open circuit
Valve defective

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01169
Door contact switch driver's
side -F2
Open circuit/short to Wiring short to positive Glow period system will not - Check wiring and con‐
positive Wiring open circuit activate by opening and nections according to cur‐
Switch defective closing the driver's door rent flow diagram.
Short to earth Wiring short to earth - If necessary replace
Switch defective switch.
01170
Injection period sender -
G175
Volkswagen Technical Site: http://vwts.ru http://vwts.info

4 01 - Self diagnosis
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Short to earth Wiring short to earth Control unit switches to - Check wiring and con‐
emergency function nections according to cur‐
rent flow diagram.
No signal Wiring short to earth - If necessary replace
Wiring open circuit sender.
Sender defective

V.A.G 1551 print-out Possible causes of Possible effects Fault remedy

fault
01180
Engine/AC compressor switch-off, Air conditioner is not - Check air conditioner
electrical connection switched off compressor switch-off,
=> Page 6 , final
control diagnosis
Short to positive Wiring short to positive
01204
Engine temperature sender -G27-
Open circuit/short to Wiring short to positive Glow plugs permanent‐ - Check wiring and con‐
positive Wiring open circuit ly on nections according to
Sender defective current flow diagram.
Short to earth Wiring short circuit to No glow period - Check G27 => Page
earth No idling speed boost 39
Sender defective with cold engine

V.A.G 1551 print-out
01265
Exhaust gas recirculation
valve -N18-
Short to positive
Open circuit/short to
earth
01266
Glow plug relay -J52
Short to positive
Open circuit/short to
earth
Possible causes of fault Possible effects Fault remedy
Wiring short to positive Black smoke - Check N18, => Page
Valve defective Increased emissions 6 , final control diag‐
Slightly reduced perform‐ nosis
ance
Wiring short to earth
Wiring open circuit
Valve defective
Wiring short to positive No glow period - Check wiring and con‐
Relay defective Poor cold starting nections according to cur‐
Warning lamp -K29- flash‐ rent flow diagram.
es If necessary replace re‐
lay.
Wiring short to earth
Wiring open circuit
Relay defective

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01269
Commencement of injection
valve -N108
Open circuit/short to pos‐ Wiring short to positive Misfiring and/or blue - Check N108, => Page
itive Wiring open circuit smoke when engine is 6 , final control diag‐
Valve defective cold nosis
Short to earth Wiring short to earth Coarse engine running or
Valve defective diesel knock when engine
warm

1.6 - Fault table 5

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.7 - Erasing fault memory

Special tools, testers and auxiliary items

◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3

Note:

The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.

Test conditions

• Fault eliminated

Note:

After eliminating faults the fault memory must be interrogated again as follows and then erased.

Work sequence

- Connect fault reader V.A.G 1551 and select injection pump electronics control unit (address word 41); se‐
lection is carried out with engine idling.
=> Page 1

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Input 02 for "Interrogate fault memory" function and confirm with Q.

-
Rapid data transmission HELP
Select function XX

-> Press ⇒button until all faults still stored have appeared and the display reads:
- Input 05 for "Erase fault memory" function and confirm with Q.

-> Indicated on display:

Rapid data transfer
Fault memory is erased!

- If the fault memory will not erase there is a fault still in the system and this must be rectified.
- Press ⇒ key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Input 06 for "End output" function and confirm with Q.

- Carry out a road test and interrogate fault memory again. No faults should be shown.

1.8 - Final control diagnosis

Special tools, testers and auxiliary items

◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3

◆ Diode test lamp V.A.G 1527

The final control diagnosis activates the following components in the stated sequence:

6 01 - Self diagnosis
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
1. Exhaust gas recirculation valve (N18)

2. Idling speed boost valve (N177)

(only with air conditioner)

3. Glow period warning lamp (K29)

4. Glow plug relay (J52)

5. Full load stop valve (N194)

(only engine code 1Y)

6. Engine/air conditioner compressor electrical connection

(only with air conditioner)

7. Commencement of injection valve (N108)

Notes:

◆ During the final control diagnosis the individual final controls are activated by pressing the ⇒key. They will
remain activated until the ⇒key is pressed again.
◆ The ignition must be switched off before repeating the final control diagnosis.
◆ The final control diagnosis can be carried out with the engine stationary or running. As the clicking of the
valves when being activated can be heard better with the engine stationary. it should be carried out with the
engine stationary.

Work sequence

- Connect fault reader V.A.G 1551 and select Diesel injection pump electronics control unit (address word
41); selection is carried out with ignition switched on.
=> Page 1

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Operate fault reader taking into account the information on the display:
- Input 03 for "Final control diagnosis" function.

-> Indicated on display:

Rapid data transfer Q
03 Final control diagnosis

Note:

If something different is indicated on the display =>Fault reader operating instructions.

- Confirm entry with Q key.

-> Indicated on display:

Final control diagnosis
Exhaust gas recirculation valve -N18

The valve will be activated and must click once.

- Press ⇒ button.

-> Indicated on display:

Final control diagnosis
Exhaust gas recirculation valve -N18

Valve activation will be switched off and the valve must again click once.

1.8 - Final control diagnosis 7

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Valve does not click:

- Checking exhaust gas recirculation:

=> 4-Cyl. Diesel engine, Mechanics; Repair group 26; Checking exhaust gas recirculation Checking exhaust
gas recirculation

- Press ⇒ button.

-> Indicated on display:

Final control diagnosis
Idling speed boost valve -N177

The valve will be activated and must click once.

- Press ⇒ button.

-> Indicated on display:

Final control diagnosis
Idling speed boost valve -N177

Valve activation will be switched off and the valve must again click once.

Valve does not click:

- Check wiring and connections according to current flow diagram.

- Check idling speed boost valve => Page 40
- Press ⇒ button.

-> Indicated on display:

Final control diagnosis
Glow period warning lamp -K29

The warning lamp must light up.

Warning lamp does not light up:

- Check glow period warning lamp:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

- Press ⇒key.

-> Indicated on display:

Final control diagnosis
Glow period warning lamp -K29

The warning lamp must go out.

- Press ⇒ button.

-> Indicated on display:

Final control diagnosis
Glow plug relay -J52

The glow period is switched on and the relay must click once

- As a check the diode test lamp V.A.G 1527can be connected to the glow plug feed wire.
LED must light up.
- Press ⇒key.

-> Indicated on display:

8 01 - Self diagnosis
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

Final control diagnosis

Glow plug relay -J52

The glow period is switched off and the relay must again click once or LED must go out.

If the relay does not click:

- Check glow plug relay:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

- Press ⇒key.

-> Indicated on display:

Final control diagnosis
Engine/ACC electrical connection

The air conditioner compressor must stop within 5 secs. (visual check), and then start running again.

If the conditioner compressor is not switched off:

- Check conditioner compressor shut-off:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

- Press ⇒key.

-> Indicated on display:

Final control diagnosis
Engine/ACC electrical connection

- Press ⇒key.

-> Indicated on display:

Final control diagnosis
Full load stop valve N194

The valve will be activated.

- As a check the diode test lamp V.A.G 1527can be connected to the full throttle stop valve feed wire.
LED must light up.
- Press ⇒key.

-> Indicated on display:

Final control diagnosis
Full load stop valve N194

Valve activation is switched off and the LED must go out.

If LED does not light up:

- Check wiring and connections according to current flow diagram.

- Check full load stop valve=>Page 40
- Press ⇒key.

-> Indicated on display:

Final control diagnosis
Commencement of injection valve -N108

The valve will be activated and must click once.

- Press ⇒key.

1.8 - Final control diagnosis 9

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
-> Indicated on display:
Final control diagnosis
End output

Valve activation is switched off and the valve must again click once.

Valve does not click:

- Check wiring and connections according to current flow diagram.

- Check commencement of injection valve => Page 38
- Press ⇒key.

-> Indicated on display:

Function is not known
or cannot be performed at the moment

- Press ⇒ button.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Input 06 for "End output" function and confirm with Q.

- Switch off ignition.

1.9 - Reading measured value block

Currently only display group 01 can be read in the measured value block, for the following values:

Display zones
1 2 3 4
Display group 01
Display xxxx rpm xx.x ms xxx.x % xx.x mm3
Indica‐ Engine Injec‐ Com‐ Quantity
ted speed tion pe‐ mencement injected
riod of injection
valve
switched-
on period

Special tools, testers and auxiliary items

◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3

Test conditions

• Engine oil temperature min. 80 °C

• All electrical consumers switched off.

Work sequence

- Connect fault reader V.A.G 1551 and select Diesel injection pump electronics control unit (address word
41); selection is carried out with engine idling.
=> Page 1

-> Indicated on display:

Rapid data transfer HELP
Select function XX

10 01 - Self diagnosis
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- Press keys 0 and 8.
(With 08 the function "Read measuring value block" is selected)

-> Indicated on display:

Rapid data transfer Q
08 - Read measuring value block

- Confirm entry with Q key.

-> Indicated on display:

Read measuring value block Q
Enter display group number XX

- Input 01 for "Display group number" and confirm with Q.

-> Indicated on display

Read measured value block 1
930 rpm - 37.0 % 5

- Read off idling speed in display zone 1.

Specification: 900± 30 rpm
- Disregard injection period in display zone 2 (no specification).
- Read off commencement of injection valve switched-on period in display zone 3.
Specification: 10...90%
- Read off quantity injected in display zone 4.
Specification: 1...14
- If the specifications in display zone 3 and 4 are not attained, replace injection period sender (G175)
=> Page 17 .

1.9 - Reading measured value block 11

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

23 - Mixture preparation, Injection

1 - Servicing fuel injection system

1.1 - Servicing fuel injection system

From 10.94 the injection pumps are fitted with a split injection pump sprocket, actuator for idling speed boost,
sender for injection period, valve for start of injection and, for normally aspirated diesel engines, a full load stop
valve.

Rules for cleanliness=> Page 19

Checking fuel system for leaks => Page 20

Actuator controlled load-dependent injecting timing

=>Page 21

Actuator for idling speed boost

=>Page 38

Valve for start of injection=>Page 38

Full load stop valve (N194)=>Page 40

Notes:

◆ Hose connections are secured with screw-type or spring-type clips.

◆ Always renew spring-type clips with screw-type clips.
◆ Always renew seals and gaskets.

12 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.2 - Injection pump with two-part sprocket

Injection pump with two-part sprocket

=>Page 16

1 Woodruff key
◆ Check seated securely
2 Injection pump
◆ Fill with Diesel before installing
◆ Removing and installing
=> Page 21
◆ Adjusting pump timing
=> Page 28
◆ With the exception of repairs described on Page 45 , pump must be replaced if faulty as an injection
pump test bench is required for repairs.
3 Supply pipe
◆ From fuel filter
4 25 Nm
Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.2 - Injection pump with two-part sprocket 13

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

5 Injector pipes
◆ Tighten to 25 Nm
◆ Remove with 3035
◆ Always remove pipework complete
◆ Do not alter shape
6 Return pipe
◆ From injector
7 Injector, 70 Nm
◆ Removing and installing
=> Page 41
◆ Servicing => Page 42
8 Heat shield
◆ Replacing
◆ Fitting position => Page 41
9 25 Nm
◆ Banjo-bolt for return pipe
◆ Is marked with "OUT"
10 Return pipe
◆ To control valve/fuel filter

14 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

11 15 Nm
◆ May be tightened to 25 Nm if leaks occur
12 25 Nm
13 Bracket
14 Sleeve
◆ Tapered
15 25 Nm
16 25 Nm
◆ Nut with taper
17 Console
18 25 Nm
19 Injection pump sprocket
◆ Removing => Removing injection pump Page 21
20 45 Nm

1.2 - Injection pump with two-part sprocket 15

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.3 - Injection pump with two-part sprocket

Injection pump with one-part sprocket

=>Page 13

1 Idling speed boost actuator

◆ Pneumatic for vehicles with air conditioner
◆ Adjusting => Page 38
2 Bracket
3 10 Nm
4 20 Nm
5 Clamping piece
6 Injection pump sprocket
◆ Two part

16 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

7 25 Nm
8 Clamping piece
9 Protective cap
10 Bracket
11 Idling speed boost actuator (N123)
◆ Electric for vehicles without air conditioner
◆ Adjusting => Page 38
12 Commencement of injection valve (N108)
◆ Checking =>Page 6 , final control diagnosis
13 Injection period sender (G175)
◆ Tighten to 25 Nm
14 Sealing ring
◆ Renew

1.3 - Injection pump with two-part sprocket 17

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.4 - Servicing fuel filter

1 Return pipe
◆ From injection pump
2 Supply pipe
◆ To injection pump
3 O-Ring
◆ Renew
4 Control valve
◆ Installation position: arrow points towards fuel tank
◆ When changing filter, remove securing clip and take control valve off complete with fuel pipes
◆ Below + 15 °C:
Passageway to filter open
◆ Over + 31 °C:
Passageway to filter closed

18 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

5 Securing clip
6 Return pipe
◆ To fuel tank
7 Supply pipe
◆ From fuel tank
8 Fuel filter
◆ Fill with diesel before installing
◆ Flow direction is marked by an arrow
◆ Do not interchange connections
9 Gasket
◆ Renew if damaged
10 Water drain plug
◆ To bleed remove securing clip and take control valve off complete with fuel pipes attached
◆ Loosen and allow approx. 100 cm3 fluid to drain

1.5 - Rules for cleanliness

When working on the fuel supply/injection system, pay careful attention to the following "5 rules":

1.4 - Servicing fuel filter 19

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
◆ Also ensure that no Diesel fuel runs onto the coolant hoses. If necessary hoses must be cleaned immedi‐
ately. Affected hoses must be replaced.

1.6 - Checking fuel system for leaks

Special tools, testers and auxiliary items

◆ Hand pump V.A.G 1274

◆ Adapter V.A.G 1274/1 A
◆ Adapter V.A.G 1274/2
◆ Hose clip

Test sequence

- Run engine at idling speed and open the throttle several times to remove any air which may be in the system.

- Disconnect return pipe from injection pump.

- -> Secure adapter pipe to the injection pump in place of the return pipe.
- Clamp-off supply pipe at fuel tank with a hose clamp.
- Using tester hand pump build-up a pressure of
1.0 ... 1.5 bar.
It may be necessary to pump up the system several times because of air which may be in the system.
- If the pressure constantly drops, locate leak and eliminate fault.

Notes:

◆ The fault can be localised by repositioning the hose clamp, e.g. to in front of the fuel filter.
◆ The return pipe can be pressurized by connecting the adapter to the injector supply pipe. Then the return
and supply pipes at the fuel tank as well as the supply pipe at the fuel filter outlet must be disconnected.

20 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.7 - Actuator controlled, load-dependent injection timing

Engine code AAZ

Special tools, testers and auxiliary items

◆ Diode test lamp V.A.G 1527

-> The actuator controlled load-dependent injection timing is integrated into the injection pump. It has the task
of adjusting the injection timing according to the load on the engine. This adaption achieves a softer running
engine.
Above approx. 2800/rpm the load-dependent injection timing is cut-off by actuator (N165) -1-, which is controlled
by the automatic glow period control unit (J179).

Checking cut-off:

- Pull connector off actuator.

- Connect diode test lamp V.A.G 1527 to connector.
- Start engine and raise engine speed to approx. 3000/rpm:
the test lamp must light up.
- Test lamp does not light up: locate fault according to current flow diagram, or renew automatic glow period
control unit (J179).

Checking actuator

- Remove actuator, connect to earth and voltage supply:

Actuator must operate.

1.8 - Removing and installing injection pump

Special tools, testers and auxiliary items

◆ Setting bar 2065 A

◆ Torque wrench V.A.G 1331 (5...50 Nm)
◆ Pin wrench Matra V159
◆ Ring spanner 3035

For one piece injection pump sprocket:

◆ Pin 2064
◆ Puller 3032

For two-part injection pump sprocket:

◆ Pin 3359

1.7 - Actuator controlled, load-dependent injection timing 21

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
◆ Spade terminal release tool

Engines without semi-automatic tensioning roller:

◆ V- and toothed belt test unit VW 210

Injection pumps with one piece injection pump sprocket

Injection pumps with two-part sprocket

=>Page 24

Removing

- -> Turn crankshaft to TDC No. 1 cylinder -arrow-.

- Lock camshaft with setting bar.
- Centralize setting bar as follows:
Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the
gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting
bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler
gauge, of same thickness, at the other end between setting bar and cylinder head.

- Remove toothed belt from camshaft and injection pump sprockets.

- Remove injection pump sprocket securing nut.
- -> Loosen puller arms and offer up.
- Locate puller arms through holes in injection pump sprocket and tighten.
- Place injection pump sprocket under tension with puller.
- Release injection pump sprocket from injection pump taper by tapping on spindle of puller -arrow- (thereby
hold sprocket so that it does not fall off).

22 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Note:
Use open ring spanner 3035 to remove high pressure fuel pipes.
- Remove all fuel pipes from pump and cover openings with clean cloth.

- Remove engine shut-off cable.

- Detach accelerator and cold start accelerator cable.
- -> Remove securing bolts from console -arrows-.

Note:
On no account should the bolts holding the injection pump head be loosened. Loosening these bolts allows the
head to cant and caurses the distributor plungers to fracture.

- -> Remove bolt from rear support -arrow-.

Installing
- Install injection pump and align to centre position in the flange elongated holes.
Tightening torque:
Securing bolts: 25 Nm
Fuel pipes: 25 Nm
Injection pump sprocket: 45 Nm

1.8 - Removing and installing injection pump 23

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Note:
Do not interchange fuel supply and return pipe banjo bolts the return pipe banjo bolt has a smaller internal
diameter and "OUT" is marked on the hexagon head.
- -> Install injection pump sprocket and lock in position with pin 2064.
- Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping
with a hammer (using a drift through rear toothed belt guard opening).
- Check whether TDC mark on flywheel and reference mark are aligned.

- Place toothed belt on and remove injection pump sprocket locating pin.
- -> Tension toothed belts (turn tensioner with pin wrench e.g. Matra V159 -arrow- to right).
Scale value: 12 ... 13
measured between camshaft sprocket and injection pump sprocket.
- Tighten camshaft sprocket securing bolt to
45 Nm.
- Remove setting bar.
- Turn crankshaft two rotations in engine D.O.R. and again check toothed belt tension.
- Checking injection timing => Page 28
- Checking and adjusting idling speed and governed speed => Page 34

Injection pumps with two-part injection pump sprocket

Injection pumps with one-piece sprocket

=>Page 22
Removing
- Remove air cleaner.
- Remove upper toothed belt guard.

24 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- Remove cylinder head cover.
- -> Turn crankshaft to TDC No. 1 cylinder -arrow-.
- Lock camshaft with setting bar.

- Centralize setting bar as follows:

Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the
gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting
bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler
gauge, of same thickness, at the other end between setting bar and cylinder head.

- -> Lock injection pump sprocket with pin 3359.

- Loosen injection pump sprocket securing bolts -1-.
- Loosen tensioner.
- Take off toothed belt.

Note:

Use open ring spanner 3035 to remove high pressure fuel pipes.

- Remove all fuel pipes from pump and cover openings with clean cloth.
- -> Separate multi-pin connector -1- and unclip from retainer.
- Disconnect earth cable -2-.
- Separate connections for oil pressure switch, coolant temperature sender and feed wire for glow plugs.

1.8 - Removing and installing injection pump 25

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

Attention!
On no account must the injection pump hub nut -1- be loosened.
Otherwise the injection pump basic setting will be upset, and it cannot be adjusted with normal workshop
equipment.

- -> Remove securing bolts from console -arrows-.

- -> Remove bolt from rear support -arrow-.

- Take off injection pump with multi-pin connector.

Installing

26 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
-> If the injection pump is replaced, the spade contacts must be pushed out of the multi-pin connector with the
spade terminal release tool.
1- Spade terminal release tool
2- Multi-pin connector

Injections pumps supplied as a replacement part, are not fitted with a multi-pin connector. The spade connectors
on the wires must be located in the multi-pin connector in accordance with the current flow diagram:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
- Insert injection pump in console and then tighten securing bolt on rear support with conical nut first.

- Insert front securing bolts and tighten to 25 Nm.

- -> Fit injection pump sprocket, screw in securing bolts -1- loosely and align to middle position in the elongated
holes.
- Lock injection pump sprocket with pin 3359.

- -> Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by
tapping with a hammer (using a drift through rear toothed belt guard opening).
- Fit toothed belt to injection pump sprocket and tensioning roller.
- Fit camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still
turn).

1.8 - Removing and installing injection pump 27

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- -> Turn tensioning roller with pin wrench (e.g. Matra V159) to right until notch aligns with raised portion
(arrows).
- Tighten lock nut on tensioning roller.
Tightening torque: 20 Nm
- Check again whether TDC mark on flywheel and reference mark are aligned.
- Tighten camshaft sprocket securing bolt to
45 Nm.
- Tighten injection pump sprocket securing bolts to
25 Nm.
- Remove setting bar.

- Remove pin.
- Turn crankshaft two rotations in engine D.O.R. and set again to TDC No. 1 cylinder.
- -> Check whether injection pump sprocket can be locked with pin 3359.

If the injection pump sprocket cannot be locked:

- Loosen injection pump securing bolts -1-.

- Turn injection pump sprocket hub until the pin fits.
- Tighten injection pump sprocket securing bolts to
25 Nm.

Note:

Do not interchange fuel supply and return pipe banjo bolts the return pipe banjo bolt has a smaller internal
diameter and "OUT" is marked on the hexagon head.

- Reconnect injection pipes, fuel pipes and electrical wiring.

- Install toothed belt guard, cylinder head cover and air cleaner.

1.9 - Checking and adjusting injection pump timing

Special tools, testers and auxiliary items

◆ Torque wrench V.A.G 1331 (5...50 Nm)

◆ TDC setting appliance 2068A

For one-piece injection pump sprocket:

◆ Adjusting lever 3210

◆ Dial gauge
◆ Dial gauge adapter 2066

For two-part injection pump sprocket:

◆ Pin 3359
◆ Setting bar 2065 A

28 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Injection pumps with one-piece injection pump sprocket

Injection pumps with two-part sprocket

=>Page 30

Checking and adjustment conditions

• Toothed belt tension OK.

• Cold start accelerator must not be pulled out (operating lever of fuel injection pump in 0 position).

Work sequence

- Set engine to TDC No.1 cylinder.

-> Engine installed:

- Turn crankshaft until TDC mark on flywheel is aligned with mark on clutch bell housing.

-> Engine removed:

- Screw-in adjusting tool as shown.

- Set adjusting tool to 5.0 mm. The left notch of the vernius -arrow A- is the reference point.
- Turn crankshaft until TDC mark on the flywheel is aligned with the tip of the adjusting tool -arrow B-.

Checking and adjusting

- Remove plug from injection pump head.

Notes:

◆ Always renew plug seal.

1.9 - Checking and adjusting injection pump timing 29

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

◆ Tightening torque 15 Nm.

◆ May be tighten to max. 25 Nm if leaks occur.

- -> Screw in adapter and small dial gauge (measuring range 0...3.0 mm) in place of plug and preload dial
gauge to approx. 2.5 mm.
- Slowly rotate crankshaft against engine direction of rotation (anti clockwise) until the pointer of the dial gauge
no longer moves.
- Set dial gauge to "0" with approx. 1 mm preload.
- Rotate crankshaft in engine direction of rotation (clockwise) until TDC marking on the flywheel is aligned
with the reference mark.
- Read of start of injection on dial gauge

Engine code letters AAZ

Testing value: 0.73 ... 0.87 mm
Set value: 0.80±0.02 mm)

Engine code letters 1Y

Testing value: 0.83 ... 0.97 mm
Set value: 0.90±0.02 mm )

Note:
No resetting is necessary provided the test figure is within the specified tolerance.
- To adjust, loosen the three bolts on the bracket and the securing bracket on the rear support.
- Adjust commencement of delivery to the specified figures by turning the injection pump with adjusting lever
-3210-.
- Tighten securing bolts to25 Nm.

Injection pumps with two-part injection pump sprocket

Injection pump with one-part sprocket

=>Page 29

30 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Test conditions
• Toothed belt tension OK.

Work sequence
- Set engine to TDC No.1 cylinder.
- -> Turn crankshaft until TDC mark on flywheel is aligned with mark on clutch bell housing.
- Remove upper toothed belt guard.

- -> The pin 3359 must fit in the hole in injection pump sprocket and injection pump.

If the pin cannot be pushed into the holes, the commencement of injection must be reset as follows:
- Remove air cleaner.
- Remove cylinder head cover.

- -> Lock camshaft with setting bar.

- Centralize setting bar as follows:
Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the
gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting
bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler
gauge, of same thickness, at the other end between setting bar and cylinder head.

1.9 - Checking and adjusting injection pump timing 31

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- -> Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by
tapping with a hammer (using a drift through rear toothed belt guard opening).

- -> Loosen injection pump sprocket securing bolts -1-.

- Turn injection pump hub until the pin fits.
- Check again whether TDC mark on flywheel and reference mark are aligned.
- Tighten camshaft sprocket securing bolt to
45 Nm.
- Tighten injection pump sprocket securing bolts to
25 Nm.
- Remove setting bar.

- Remove pin.
- Turn crankshaft two rotations in engine D.O.R. and set again to TDC No. 1 cylinder.
- -> Check whether injection pump sprocket can be locked with pin 3359.

If the injection pump sprocket cannot be locked:

- Loosen injection pump securing bolts -1-.
- Turn injection pump sprocket hub until the pin fits.
- Tighten injection pump sprocket securing bolts to
25 Nm.

- Install toothed belt guard, cylinder head cover and air cleaner.

1.10 - Checking valve timing

For injection pumps with two-part injection pump sprocket

=>Page 30 adjusting commencement of injection.
Special tools, testers and auxiliary items
◆ Torque wrench V.A.G 1331 (5...50 Nm)
◆ Setting bar 2065 A
◆ TDC setting appliance 2068A
◆ Pin 2064 (one-piece sprocket)

32 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
◆ Pin 3359 (split sprocket)

Injection pumps with one-piece injection pump sprocket

Work sequence
- Remove upper toothed belt guard and cylinder head cover.
- Check tension of toothed belt.
- -> Set engine to TDC No. 1 cylinder -arrow-. Setting bar must fit into the camshaft slot. If it is not possible
to insert the bar, adjust valve timing as follows.
- Rotate camshaft so that setting bar can be inserted.
- Centralize setting bar as follows:
Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the
gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting
bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler
gauge, of same thickness, at the other end between setting bar and cylinder head.

- Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping
with a hammer (using a drift through rear toothed belt guard opening).
- -> Lock injection pump sprocket with pin 2064.
- Check TDC, if necessary turn crankshaft until TDC mark on flywheel aligns with mark on bell housing =>
Fig. 23-169, Page 33

Note:
It may be necessary to remove the toothed belt in order to set the injection pump sprocket and the TDC marking
on the flywheel.
- Remove pin.
- Tension toothed belt and tighten camshaft securing bolt to 45 Nm.

1.10 - Checking valve timing 33

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- Remove setting bar.
- Check injection pump timing
=>Page 28

1.11 - Adjusting idling speed, idling speed boost and engine governed speed

Special tools, testers and auxiliary items

◆ Ignition tester V.A.G 1367
◆ Adapter VW 1324
◆ T spanner 3231

Checking and adjustment conditions

• Oil temperature at least 60 °C.
• Cold start accelerator cable must not be pulled.
• Electric consumers switched off.

Injection pumps with one-piece injection pump sprocket

Injection pump with two-part sprocket

=>Page 35
Idling speed
The rpm can be measured using V.A.G. 1367 ignition tester with the TDC-sender or VW 1324 adapter.

- -> Adjust by turning the idling speed adjusting screw -1-

Setpoint value: 900±30/min

Note:
If by adjusting the screw on the adjustment lever -1- the idling speed cannot be set below 930 rpm because
the adjustment lever -3- is against the stop screw -2- then continue as follows:

34 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- -> Release stop screw -2- for lower idling speed and screw back.
- Set idling speed at adjusting lever -1- to 900 rpm.
- Turn stop screw -2- until it contacts the adjusting lever -3- and then lock lock nut.

Checking and if necessary adjusting idling speed boost

- When pulling the CSA cable out to the first stage the engine speed will increase by approx. 60 rpm.
With the cable fully pulled out the engine speed must increase to 1050 ± 50 rpm.

If idling speed is not to specification 1050± 50 with cable pulled fully out:

- -> Release stop screw -arrow- and, with CSA cable fully withdrawn, set higher idling speed by turning stop
screw to 1050 rpm.
- Lock stop screw.

Injection pumps with two-part injection pump sprocket

Injection pump with one-part sprocket

=>Page 34

Idling speed

The engine speed can also be measured in measured value block of self-diagnosis with fault reader V.A.G
1551.

- -> Adjustment is by turning the idling speed adjustment screw -1-, with the T spanner 3231.
Specification: 900± 30 rpm

Idling speed boost

When engine is cold or when switching on the air conditioner the idling speed will be increased by the idling
speed boost actuator.

1.11 - Adjusting idling speed, idling speed boost and engine governed speed 35
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

- -> With the engine warm, press the stop lever manually to the end position of adjusting screw -2-; rpm must
increase to 1050±50 rpm

If idling speed is not to specification 1050± 50 rpm:

- Release stop screw locking nut -2- and adjust increased idling speed to 1050 rpm by turning the stop screw.
- Lock stop screw.

1.12 - Load change speed

Checking and adjustment conditions

• Engine - no load

- -> Open throttle fully and adjust rpm with adjustment screw -arrow-.
- For one-piece injection pump sprocket
Specification: 5200±100 rpm
- For two-part injection pump sprocket
Specification: 5050±100 rpm
- Lock adjusting screw.

36 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.13 - Residual volume basic setting

-> The residual volume screw -arrow- must not normally be altered.

The manufacturer sets the so-called residual volume via this screw on a test bench..

If the screw has nevertheless been altered, this may result in the following complaints:

◆ Screw turned in = residual volume too large.

In this case the engine runs too fast and it is not possible to set idling speed.
◆ Screw turned out (gap at adjusting lever) = residual volume too small.
This causes performance faults such as "flat spot" when pulling away and accelerating from low engine rpm
or jerking in all gears.

If such faults occur, the following basic setting must be performed at the residual volume adjusting screw.

- -> Release adjusting screw -arrow- lock nut.

Residual volume too low: (Performance faults)

- Screw adjusting screw in until idling speed increases.

- Turn adjusting screw back a half turn from the point at which the idling speed increases.

Residual volume too large: (Engine speed too high)

- Unscrew adjusting screw until engine speed no longer decreases.

- Screw in adjusting screw again until idling speed increases.
- Turn adjusting screw back a half turn from the point at which idling speed increases.
- Lock adjusting screw.

1.13 - Residual volume basic setting 37

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.14 - Idling speed boost actuator

When the engine is cold or when switching on the air conditioner the idling speed will be increased by the idling
speed boost actuator. If this actuator is replaced, it is to be connected as follows with the engine cold:
Electrical actuator
For vehicles without air conditioner
- -> Press adjustment lever -1- against the stop screw for idling speed adjustment screw -arrow- and connect
clamping piece -2- firmly

Pneumatic actuator

For vehicles with air conditioner

- -> Press adjustment lever -1- against the stop screw for idling speed adjustment screw -arrow- and connect
clamping piece -2- firmly

1.15 - Checking commencement of injection valve

Volkswagen Technical Site: http://vwts.ru http://vwts.info

38 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Special tools, testers and auxiliary items

◆ Hand multimeter V.A.G 1526

Test sequence

- -> Separate multi-pin connector -1- and unclip from retainer.

- Carry out resistance measurement between contacts 2 + 3 using hand multimeter V.A.G 1526.
Specification: 12 ... 20 ω

Multi-pin connector assignment:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

If the specification is not attained:

- Replace commencement of injection valve (N108)

=>Page 17

1.16 - Checking engine temperature sender

Special tools, testers and auxiliary items

◆ Hand multimeter V.A.G 1526

Test sequence

- Switch off ignition.

- -> Pull connector -1- off sender.
- Perform resistance measurement between sender -2- sockets 1 + 3 using hand multimeter; Specification
=> table.

1.17 - Resistance figures for engine temperature sender

Temperature Resistance figure Temperature Resistance figure

-20°C 5.40....7.30kω +20°C 0.922 1.158kω
-15°C 4.30...5.70kω +60°C 225...265ω
-10°C 3.30...4.30kω +90°C 96...108ω
-05°C 2.70...3.40kω +120°C 44.5...50.5ω
0°C 2.13....2.77kω

If the specification is not attained:

1.15 - Checking commencement of injection valve 39

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- Replace coolant temperature sender.

1.18 - Checking idling speed boost valve

Special tools, testers and auxiliary items

◆ Hand multimeter V.A.G 1526

Test sequence

- Pull connector of valve (next to fuel filter).

- -> Measure resistance at valve.

Specification: 50 ... 65 ω

If the specification is not attained:

- Replace valve.

1.19 - Check full load stop valve, engine 1Y

Special tools, testers and auxiliary items

◆ Hand multimeter V.A.G 1526

- -> The normally aspirated diesel engines are fitted with a full load stop valve -1-. This reduces the upper full
load quantity.
- Perform resistance measurement with multimeter V.A.G 1526 between voltage supply connection and earth:
Specification: 8...12 ω (at room temperature)

40 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

1.20 - Removing and installing injectors

Note:
Defective injectors cause the following faults:
◆ Misfiring
◆ Knocking in one or more cylinders
◆ Engine over-heating
◆ Loss of power
◆ Excessive black exhaust smoke
◆ Higher fuel consumption
◆ Excessive blue smoke when starting from cold

Defective injectors can be located by loosening the high pressure pipe union on each injector in turn with the
engine running at a fast idling speed. If engine speed remains constant after loosening a pipe union, this indi‐
cates a defective injector.
Special tools, testers and auxiliary items
◆ Torque wrench V.A.G 1332 (40 - 200 Nm)
◆ Ring spanner 3035
◆ Socket wrench insert 3376

Removing
Note:
Always remove pipe set complete. Do not alter pipe shape.
- Remove injectors with 3376 socket wrench insert.

Installing

Note:
Always renew heat shield between cylinder head and injectors.

1.20 - Removing and installing injectors 41

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
-> Installation position of heat shield:
Arrow points towards cylinder head.
Tightening torques:
Injection pipes = 25 Nm
Injectors = 70 Nm

1.21 - Servicing injectors

Special tools, testers and auxiliary items

◆ Torque wrench V.A.G 1332 (40 - 200 Nm)
◆ Injection valve tester V.A.G 1322

Engine code AAZ

This engine is equipped with dual spring injectors. The fuel injected therefore occurs in 2 stages.
If faults occur with these injectors then they are to be exchanged as neither servicing nor pressure setting is
possible.
It is possible to test the first injection pressure and the seals as described on page 43 .

Engine code 1Y
- -> Clamp top of injector in vice and release screw connections.
- To ensure that the separate parts do not fall apart, clamp the bottom part of the injector and dismantle the
nozzle.

When dismantling the nozzle make sure that the individual parts are not mixed up.

42 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Tightening torque:
Injector upper and lower parts 70 Nm
-> Injector components
1- Injector upper part
2- Shim
3- Nozzle valve spring
4- Pressure pin
5- Nozzle valve retainer insert
6- Nozzle valve (needle)
7- Nozzle body
8- Injector
9- Heat insulating seal

1.22 - Checking injector nozzle valve tip for damage, injection pressure and for leakage.

Checking injector nozzle valve tip for damage

(Visual check)
If the injector pin is damaged, e.g. broken or bent, replace the injector nozzle or the needle in the nozzle body.

-> Checking opening pressure

Warning!
When testing injectors ensure that the jet of fuel does not contact the hands as the high pressure will cause
the fuel to penetrate the skin and may cause severe injuries.

Engine code AAZ

• Pressure gauge on

- Move pump lever down slowly. When spray begins, read off opening pressure. For deviations from speci‐
fication renew injector.
Specification:
new injectors: 150 ... 158 bar
Wear limit: 140 bar

Engine code 1Y
• Pressure gauge on

- Move pump lever down slowly. When spray begins, read off opening pressure and, if necessary, correct by
replacing the shim.
Specification: (excess pressure)

1.21 - Servicing injectors 43

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
new injectors: 130 ... 138 bar
wear limit: 120 bar

Note:
When servicing used injectors adjust breaking pressures to specifications for new injectors.
◆ Thicker shims increase breaking pressure.
◆ Thinner shims decrease breaking pressure.
◆ Increasing spring compression by 0.5 mm increases breaking pressure by 5.0 bar

Adjustment shims are available from 1.00...1.95 mm thick and increase by 0.5 mm. Use box 3065 to store
shims.
Checking for leaks
• Pressure gauge on

- Move pump lever down slowly and maintain a pressure of approx. 110 bar for 10 seconds. No fuel should
leak from the nozzle tip.

2 - Servicing injection pump

2.1 - Servicing injection pump

Volkswagen Technical Site: http://vwts.ru http://vwts.info

44 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

The following sealing operations can be performed on the injection pump:

◆ Observe rules for cleanliness
=>Page 19
◆ Removing and installing throttle lever or return spring => Page 50
◆ Renewing throttle lever bush -36-, throttle lever O ring -34- and seal -32- between pump cover and pump
body => Page 53
◆ Renewing O ring -11- for fuel delivery adjustment screw => Page 56
◆ Renewing O ring -3- for idling speed boost shaft
=> Page 56

◆ Renewing O ring -28- for timing control cover => Page 57

◆ Renewing O ring -20/22- for CSA lever/cover => Page 57

1 10 Nm
2 Injection pump cover
3 O-Ring
◆ Renewing => Page 56
4 Thrust ring
5 Idling speed lever
6 10 Nm
7 Circlip

2.1 - Servicing injection pump 45

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
◆ Lever off with screwdriver

8 Spring
9 Upper spring plate
10 Lower spring plate
11 O-Ring
◆ Renewing => Page 56
12 Washer
13 Fuel delivery adjustment screw
◆ Mark installation position
14 Idling speed adjustment rod
15 Spring washer
16 Washer
17 CSA lever
◆ Mark installation position

46 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

18 Retainer for CSA lever

19 Thrust ring
20 O-Ring
◆ Renewing => Page 57
21 CSA cover
22 O-Ring
◆ Renewing => Page 57
23 Fuel shut off valve, 40 Nm
◆ Must click when ignition switched on and off
24 O-Ring
◆ Renew
25 Valve with spring
◆ Renew together with fuel shut off valve

2.1 - Servicing injection pump 47

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

26 Pipe connection with pressure valve

◆ Removing, installing and sealing => Page 58
27 Shims
◆ Do not change assembly sequence
28 O-Ring
◆ Renewing => Page 57
29 Spring for timing control
30 Cover for timing control
31 Throttle lever shaft
◆ Press out with screwdriver handle
32 Gasket
◆ Renewing => Page 53 without renewing bush

48 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

33 Thrust washer
34 O-Ring
◆ Renew
35 Idling speed spring
◆ Unhook when removing pump cover
◆ Do not over tension
36 Bush
◆ Renewing => Page 53
37 Idling speed boost shaft
38 Thrust washer

2.1 - Servicing injection pump 49

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

2.2 - Removing and installing throttle lever or return spring

Work sequence=>Page 52

1 10 Nm
2 Washer
3 Upper spring plate
4 Load change damping spring
5 Guide bush
6 Lower spring plate
7 Upper throttle lever
8 Shim
9 10 Nm
10 Washer

50 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

11 Lower throttle lever

◆ Mark installation position relative to throttle lever shaft
12 Upper spring plate
13 Return spring
14 Lower spring plate
15 Throttle lever shaft

2.2 - Removing and installing throttle lever or return spring 51

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Removing

Note:

-> When removing and installing the lower throttle lever, ensure that the position of the throttle lever -11- relative
to the throttle lever shaft -15- is not altered.
- Check that idling speed and engine governed speed are as specified; adjust if necessary.
- Disconnect throttle cable.
- Loosen securing bolt -1-; to do this hold outer edge of washer -2- with water pump pliers and loosen bolt
with a sharp jerk.

Note:
Proceeding in this manner ensures that the securing bolt -1- is loosened and not the securing nut -9-.
- Loosen securing bolt -1- a few turns and detach load change damping spring -4- using a wire hook.

- -> Remove upper throttle lever -7- with spring -4- plates -3-, -6- and guide bush -5-.
- Remove thrust washer -8-.
- Detach return spring -13-.

52 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- Loosen securing nut -9-.
- Press lower throttle lever -11- onto throttle lever shaft splines -15-, remove securing nut -9- and washer -10-.
- Mark installation position of throttle lever -11- relative to throttle lever shaft -15-.
- Remove throttle lever and return spring -13- with spring plates -12- and -14-.

Installing

- Install return spring -13- together with spring plates -14- and -12-.
- Install lower throttle lever -11- in marked position, fit washer -10- and tighten securing nut -9- to 10 Nm.
- Attach return spring -13-.
- Check idling speed and engine governed speed.

Notes:

◆ If, after installation the idling speed deviates only a small amount from specification - approx. 200 rpm -,
then the installation position is not to be altered.
◆ By moving the throttle lever clockwise by one spline relative to the throttle lever shaft, the engine will race
in the idling speed position at approx. 4000 rpm.

◆ By moving one spline anti-clockwise the engine will run at a considerably lower idling speed - approx. 500
rpm - or will not start without the throttle being depressed and cuts out when idling. In such cases correct
the position of the throttle lever.

- -> Fit shim -8-.

- Install upper throttle lever -7- together with lower spring plate -6-, guide bush -5-, spring -4- and spring plate
-3-.

Note:

Ensure that the guide bush -5- engages in the shim -8-.

- Install securing bolt -1- with washer -2- and tighten a few turns.
- Attach load change damping spring -4- and tighten securing bolt -1- to 10 Nm.
- Check idling speed and engine governed speed and adjust if necessary.

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

Removing return spring and lower throttle lever

2.2 - Removing and installing throttle lever or return spring 53

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
=>Page 50
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
- -> 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 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 from the idling speed adjusting rod by removing the circlip.
- -> Tip pump cover slightly to one side, and detach idling speed spring -arrow- (e.g. using locally manufac‐
tured hook). Do not over tension spring.

54 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- -> Lift pump cover slightly, press throttle lever shaft -arrow- towards the inside of the cover (e.g. with a
screwdriver handle) whilst taking the cover off.

- -> Remove pump cover and press bush 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 50 .
- Run engine until warm and check idling speed and engine governed speed.

2.3 - Renewing pump cover throttle lever bush, pump cover gasket and throttle lever shaft

O-ring 55
 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
- Check exhaust opacity with combustion tester V.A.G 1500

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

2.4 - Renewing fuel delivery adjusting screw O-ring

Note:

The smallest mal-adjustment of fuel delivery adjusting screw causes 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 fuel delivery
adjusting screw be screwed beyond the original position.

Work sequence

- -> 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 locking sleeve and unscrew fuel delivery adjusting screw from pump cover.
- Renew O-ring.
- Screw in delivery adjusting screw as illustrated.
- Run engine until warm and check idling speed and engine governed speed.
- Check exhaust gas opacity with combustion tester V.A.G 1500

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

2.5 - Renewing idling speed boost shaft O-ring

Special tools, testers and auxiliary items

◆ Torque wrench V.A.G 1331 (5...50 Nm)

56 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Work sequence

- Remove pump cover => Page 53 (without renewing throttle lever bush).
- -> Remove idling speed lever -2- securing nut -1- and take off lever.
- Press back idling speed boost shaft -6- slightly.
- Remove thrust ring -3- and O-ring -4-.
- Moisten new O-ring with Diesel before fitting.
- Reassemble idling speed boost shaft. Ensure thrust washer -5- installed and spring -7- is fitted.
- Tighten securing nut -1- to 10 Nm.
- Install pump cover => Page 53 .

2.6 - Renewing injection timing device cover O-ring

Work sequence

- Place a clean cloth beneath the injection pump.

- -> Remove cover screws -1- with commercially available key for Torx socket head screws, e.g. Hazet 2115-
T30.
- Remove cover -2- and clean.
- Renew O-ring -3- and install cover with existing shim -4-.

2.7 - Renewing CSA lever/cover O-ring

Work sequence

- Remove injection pump.

- -> Remove circlip -1- and spring washer -2- and washer -3-.

2.5 - Renewing idling speed boost shaft O-ring 57

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Note:

The installation position of CSA lever -5- relative to timing control shaft -12- is marked by notches. If the notches
are not present then the position of both parts relative to one another must be marked using a scriber.

- -> Remove circlip -4- and lever off idling speed adjusting rod -14-.
- Remove CSA lever -5-.
- Remove cover securing screws -6- and take off cover -9-.
- Renew cover/lever O-rings -8/13-.
- Install cover.
- Fit CSA lever as marked and secure.
- Install injection pump.

2.8 - Sealing injection pump connections

-> 1 -Seal

2 -Pressure valve

3 -Connections

58 23 - Mixture preparation, Injection

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
Work sequence

Note:

When changing connections do not interchange pressure valves.

- Loosen injector pipe.

- Tighten connection to 45 Nm.
- Tighten injector pipe to 25 Nm.

If the leak still persists, install new connection and new seal.

2.8 - Sealing injection pump connections 59

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991

28 - Glow plug system

1 - Checking glow plug system

1.1 - Checking glow plug system

Note:

Vehicles with engine code AAZ are fitted with a door-contact-controlled pre-glow system, i.e. pre-glow begins
automatically as soon as the driver's door is closed.

Check door contact control=>Current flow diagram

Test conditions

• Battery voltage at least 11.5 V

• Engine cold
• Voltage exists at glow plugs. No voltage, locate fault according to current flow diagram.

Special tools, testers and auxiliary items

◆ Diode test lamp V.A.G 1527

1.2 - Checking glow plug current consumption with V.A.G 1315A

Test sequence

- Connect current supply to tester.

- Place glow plug cable in current clamp.
- Press button for current measurement with current clamp.
- Preglow, start engine and run at idling speed.
- During extended glow period (approx. 180 sec.) read current consumption with engine running.
The current consumption of the glow plugs during the extended glow period is approx. 8 Amp. per glow plug.
With a glow plug current consumption of:

Current consumption Defective glow plug(s)

32 A 0
24 A 1
16 A 2
8A 3
0A 4

1.3 - Checking glow plugs

Test sequence

- Remove glow plug cable and busbar.

- Connect diode test lamp V.A.G 1527 to battery (+) and to each glow plug.
Diode lights up: Glow plug OK.
Diode does not light up: Renew glow plug

60 28 - Glow plug system

 Golf 1992 , Vento 1992 ➤
Diesel Injection and Glow Plug System - Edition 10.1991
(Tightening torque: 25 Nm)

Notes:

◆ The tightening torque of 25 Nm must not be exceeded otherwise the annular gap between glow pin and
threaded section will be squeezed together. This may cause the glow plugs to fail prematurely.
◆ If no fault is found and the engine is still hard to start, the glow plugs should be visually examined whilst
glowing (injectors removed).

1.4 - Glow plugs with burned electrodes

Burned electrodes on glow plugs are frequently caused by faulty injectors. Damage of this nature is not due to
faults in or on the glow plugs.

If damage of this nature is found -arrow- it is not sufficient merely to replace the glow plug. The injectors must
also be tested for opening pressure and leakage=>Page 42 .

1.3 - Checking glow plugs 61