[Vwdiesel] fuel injection pump reinstallation

[James Hansen]

Firstly- one very important thing- DO NOT make the belt too tight.
What seems just about right at first to a new guy is generally screaming 
tight.  DO NOT twist the belt to test the tension- it is not acceptable 
to do that.  I have strong fingers, and can twist a belt more than half 
a turn regardless of how tight you make it.  The twist method is a 
really shitty measurement method.
if you can just slide the belt back and forth with your fingers in the 
same direction as the pulley grooves on the injection pump pulley, you 
have it just right.  It will seem loose to you.  Thing is, if you start 
with a tight belt, as the engine warms up and grows taller a certain 
amount, the belt will get tight enough to destroy the input bushing on 
the injection pump.... and it will start to leak again.

Secondly to prime the pump, you are doing right.  To hurry it along a 
tad, you can remove a banjo fitting from the top of the pump and use a 
small funnel to pour clean diesel into the pump until it's full. Also 
fill the filter. Then reinstall the banjo and crank it over until the 
fuel flows.  getting all the air out with an empty filter AND an empty 
pump, will work, but will take a very long starter killing time... and 
you'd have to borrow Val's new battery charger a couple times. usually 
filling stuff up is the easier way to do it.  IT'll work the other way, 
but it's pretty easy to kill a starter that way.
hth
-James



jeremy wrote:
> Hi all,
> I have a '81 Rabbit diesel with about 135000 miles on the clock. It developed a
> leak on the pump so I took the pump out and had it resealed by a diesel shop.
> While at it I replaced the timing belt and the fuel filter. After reinstalling
> it and hooked up all the hoses and lines except kept the lines open before the
> injectors. Per Bentley manual I don't have to prime the pump just crack the
> engine until the fuel comes out the lines before the injectors. I cracked and
> cracked and cracked but no fuel was visible flowing thru the transparent line
> from fuel filter to the pump. So, I am wondering is this the best way to suck
> the fuel out of the tank? Now the new filter is empty, could that be the
> reason? 
> Any suggestion is appreciated.
> BTW, I am not able to get the tension I like on the timing belt no matter how
> high I try to lift the roller while tighting down the nut. The belt seems to
> deflect too much between the cam and pump. This is the first time I went so far
> with my limited mechanical knowledge so everything seems a bit difficult. Your
> experienced advises will certainly help.
> Thanks in advance.
> Jeremy
> 
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