[Vwdiesel] 2.4 6-cyl injection pump replacement

Charlie Stott chucklz_au at hotmail.com
Mon Apr 3 03:57:34 EDT 2006


I have replaced the engine in my LT35 with a unit from a volvo.

I can't find any manuals for this vehicle or engine (only petrol versions), 
so would appreciate some advice and help.

I have never worked on a diesel engine, but have a good understanding of 
petrol engines.

The engine came with head complete, so the camshaft timing is probably 
correct, but it would be good to check.  What is the procedure (where are 
the markings, etc)?

What is the procedure for fitting the injection pump (Bosche)?  Does anyone 
have a diagram showing the fuel connections?

I assume the pump only injects fuel to one cylinder at a time, so the pump 
needs to be set in time with the valves?  How do I make sure the correct 
injector fires?  There are grooves on the camshaft pulley, and on the pump 
pully, how do these line up?  Will I then need to fine tune somehow?

There is an electrical spade connection above the injector connections on 
the pump.  What is it for?

Thanks very much for any help that can be offered.

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