help needed reassembling pump (im an idiot) (UPDATE)

[jefinabox]

Hello,

2 weeks ago I attempted the governor mod on my 1.9td aaz mk3 golf. All was well until it came to reassembly. I overtightened the nut/extender on to the throttle input shaft and sheered it. I had to put off reassembling the pump until I had the shaft removed from the nut.

Then I went to France with work for 2 weeks.

 :roll:

Today I got the shaft out of the nut and went to get the disassembled parts to put it all back together again (there was enough thread on the shaft still for me to use). I'd carefully put the parts down in the order I removed them to make reassembly easy.

..Unfortunately they'd since been moved by someone and are a complete jumble. I can find diagrams for pumps that show how most pumps go back together but mine being a 1.9 is slightly different.

In this picture there is 1 spring:


My pump has 2 springs and a whole load of washers/spacers type things that I just dont know how to put back together.

I know I'm a big idiot but if anyone could help me I'd be very grateful. Thanks in advance

[Possum79]

http://vwdiesel.net/phpBB/viewtopic.php?t=12783&highlight=throttle+springs

Don't know if that particular post will help but there has been a few posts begfore of people not properly documenting how to put the springs back on. Do some searching and you will probably find what ever more you need.

[Smokey Eddy]

Maybe someone has a detailed picture of one assembled. If no one posts one i'll take one to show you. If you have a picture it's fairly easy to see how it goes back together. You need another set of hands though (i did at least) te springs, as springs always are, were frustrating and under load of course

[AdAm84]

I may be able to snag a bosch breakdown from the fuel shop i work at. or at least take a good look at one for you. Got a part #? send me a PM

[carrizog60]

Maybe someone has a detailed picture of one assembled. If no one posts one i'll take one to show you. If you have a picture it's fairly easy to see how it goes back together. You need another set of hands though (i did at least) te springs, as springs always are, were frustrating and under load of course

a tip:

reassemble all without putting the springs under load and at the final just pull the springs to their place.
i do that way on the bike shop and worked well on the pump too
 :wink:

[fatmobile]

Those springs can be the hardest part to mess with so...
Here's a post I started:
 http://www.vwdieselparts.com/forum/viewtopic.php?p=52081#52081

[carrizog60]

i don't want to do that method anymore as one day all the springs assembly decided to blow away almost hitting me in the face...

i now just put all back together and in the end i pull the springs with a spring puller or simply a piece of wire folded to make a bow and a plier.

[autoholic]

I here ya on those damn springs, could they make it any more complicated? What really gets me is the fact that you can't get the cover off with out completely disassembling the spring assembly!

[Op-Ivy]

Haha! I had the same problem when I put my pump back together.

I didn't have a nice tutorial like fatmobile posted either! :lol:

If you take your time and look at where the wear is, it's actually a lot easier than you would think! (Still took me an hour though...)

[jefinabox]

Thankyou so much everybody! with all the help here and a bit of just looking at stuff I've managed to get it all back together again, and the car working!

Because my throttle input shaft had sheared the nut/extender was counterbored too much and wouldn't grab, so I made a new one (well my friend did) out of a tire valve tool! Works a treat!
 
Thanks to everybody once more, what a wonderful place this forum is!

I'm just having a little problem with the car still, because my input shaft sheared I lost the marking so had no idea where to set my throttle. Lots of trial and error later and I have the car idling at 1100rpm and revving all the way to 5k

The only problem is, when I try to control the car on the clutch it is MUCH easier to stall, revs drop really quickly. And when I'm driving around the revs seem to drop a little bit slower. I shimmed the main spring and left the intermediate alone. Does anybody know of an adjustment I can make anywhere?

Thanks once more

[autoholic]

Sounds like what I am going through with my friends car, seems low on torque, stalls easy (also sounds very diesely and is smokey) It sure sounds timing related but the timing is set correctly. I need to go back into the pump, I must have screwed something up with the governor or throttle arm/linkage. I'll let you know what/if I find anything.