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    Posted by Brodie Orford on April 9, 2006, 10:45 pm, in reply to "Re: VW Carevelle 2002 2.5 tdi ACV eng code"

    Hi Jeremy,

    Has it had timing belts fitted recently? I've seen quite a few of those end up at the dealers to be sorted when things have got confused. As Roy says there is a limited adjustment available by altering the pump roller. Otherwise you will have to go back to basics and set everything up properly because the pump itself is fixed and can't be turned to adjust the timing as you would expect. I certainly struggled with my first one so I'll post my take on it here in the hope it will help someone in the future.

    Ignore the OT marks on the crank and use the mark on the flywheel, this seems to be the most common mistake. First you need to set up the front end in the normal way with the bar across the back of the cam and the front sprocket tapped loose. Then remove the bar and replace it with the pump sprocket, but leave it loose (this engine has a belt at both ends for anyone else looking!) You set the pump with a dial gauge to spec, lock it with a bolt then set up the pump belt adjustments as per Autodata.

    I know I've probably made this all this sounds horribly complicated if you haven't done one but actually once you get your head round it there is nothing new.

    Strictly speaking you are supposed to check the pump timing afterwards with a scan tool and if necessary fine tune it using the method Roy describes. This is because the pump timing is linked to the fuel temperature and as the fuel temp rises the ECU can advance the timing a bit. You read off the live fuel temp and timing figs in "Basic Settings" and plot them on a very simple graph given in the manual. (or online :-) If they converge in the shaded area given you are in business. If the timing is wildly out you should see a "timing outside range" or similar code.

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