pump resealing agony

[BP10000]

On a 95 Golf,

First question: In taking the external governor springs off (all 5 of them) I didn't get a chance to mark the accelerator arm position before it shifted. Is there a recommended procedure for locating the correct setting?

Also, in retiming the pump, trying to get the gauge into place in the end of the adapter I snapped off the checkvalve/hose connector for the vacuum pump. Is this part available separately?  Is there a danger of something shifting or flying out if I take the cover off the top of the pump?


Thanks.

[b1rdjx88]

The plastic nipple on mine broke off too.  I pulled the cover off and stuck the nipple back in with JB weld.  60k later and it's holding up fine.

[rallydiesel]

For the throttle arm, I test fit it without springs. Back off both the min and max travel screws. Now you can feel where the limits of the internal throttle travel is when you move the external throttle lever. Give yourself enough clearance between the min and max screws (about halfway in between) so you can make adjustments either way. Mark the position. Slap the springs on. Tighten her down.

P.S. I find electrical wire is a great way to pull the spring hooks onto their anchors. Just loop it around the spring hook and pull. Once the spring is anchored, just pull or cut the wire off. Wear safety glasses!!!!!!

[Hey]

for the throttle ARM, there IS a way to reinstall it. You need to check the boost pin play by removing the diaphragm.

This is the only good way since the idle can vary with the fuel screw position.

Get the boost pin needle at the maximum position and adjust the maximum throttle position screw according to this. Try to find the adjustment that gives you the maximum freedom to adjust the idle.

I know I not being very clear, but it's not very difficult. Try looking into the diaphragm hole and playing with the throttle position, you will see the pin coming out. Then use a screw driver to but the pin back in.... etc until the adjustment is ok.

look here for a detailed explanation

http://www.vwdiesel.net/phpBB/viewtopic.php?t=18856

[BP10000]

Thanks so much for the invaluable wisdom. I've got the accelerator arm about right with a little trial and a lot of error, and fixed the vacuum pump with a piece of thin-walled tubing and some silicone.

 I am getting a lot of black smoke on acceleration that I didn't have before. I never touched the max fuel screw so I think this is timing related, but I'm not sure which way. The engine also seems to have more knock/clatter than before above 2000. The power seems a little flat off the line like there is more turbo lag, but that could be my imagination. The engine starts very easily without any smoke.

I set the timing by the wrong mark initially, which caused a little bit of valve/piston noise. I just now fixed the cam timing (took me 20 minutes, I'm getting good at this!) but I didn't have the gumption to get right into fixing the pump timing. I set the pump by the before-TDC tooth on the flywheel, so that would cause it to be advanced, but I think I might have had the cold-start on, which would have a retarding effect. Maybe they canceled each other out, but that would just be too convenient.

In short, engine noisy and (black) smokey; is the timing advanced or retarded?

[burn_your_money]

I'll guess that the pump is advanced. You are using the dial indicator gauge  right?