Fuel Injector Shim Springs for ALH Engine

Hi.

Just got an open fuel injection pump from a friend, it's from a 1.9 TDI ALH engine. The ESP type is 0 460 404 977 or 038 130 107D. It's a version with a two-piece pump rotor, a 10-pin connector, and the new ribbed pump housing.

I noticed that the HD version doesn't have any shims for the return springs. In all other ESPs, including the VP37 from the Golf 3 TDI, I'm used to seeing one shim and one spring plate on each of the spring guides.

Here, on the feather guides, there are only feather dividers, and no additional adjustment washers.
Was wurde bei den neueren Pumpen gestrichen, oder sind beispielsweise die Teller zur Einstellung der Federn noch vorhanden?

If anyone has a picture of a disassembled pump (new model from an A3 or Golf 4 with a modified housing), that would also be very helpful to me.

Best regards, Matze.

No, that's fine.

"Shims" in this sense were never really used for that purpose. What exactly would you be adjusting, considering the high-pressure piston is guided within the high-pressure section?

Hi.

On all older VP37 and mechanical VE pumps, there are adjustment shims on the two springs that push the piston back into the injection unit. On each of the two spring guide bolts, on the side of the high-pressure part, there is a spring washer and an adjustment shim.

"However, the same part is missing from the ALH engine's fuel pump, and I've never seen that before."

Greetings.

vwSchrauber wrote:

No, that's fine. Shim washers in that sense never were that, anyway. What exactly do you want to adjust, where the pump piston is guided in the high-pressure section...?

No, those are adjustment shims, and they are used to adjust the pressure setting at the pump. Depending on the combination of lifting plates/distributor head installed, there are different adjustment values, which essentially define the preload with which the distributor pistons are pressed against the lifting plate. For the pump mentioned above, the value is 8.2-8.6mm. If the springs being used are outside of this tolerance, you need to compensate with the adjustment shims; otherwise, you don't.

Hi.
Okay, it looks like someone probably did a makeshift repair there. I still have plenty of shims, and I'll try to find the right KF size to make it fit properly.
Do you also have the K-dimension for the pump? In case someone else has also worked on the piston skirt.
Sure, no problem.
Best regards, Matze.

K-size 3.6-3.8mm

Hi.
I thought the same thing about the 3.1 mm travel distance, thank you!
Then that at least works...
Greetings.

Quote:

Then someone probably did a quick and dirty fix there

.

Apparently, a lot of these pumps are being tampered with. I've opened up quite a few where there were no membranes inside (and it's not just VAG brands).

Quote:

Adjustment washers, and these are used to adjust the KF value at the pump.

Please explain that in more detail.
So far, all the VE pump disassembly jobs I've done have revealed a rather aggressive spring preload, both with and without shims.