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[T3] Mechanical fuel pump: re-assembly

I was talking with Dan O'Donnell this evening about rebuilding his 
'67 fuel pump. I knew I had read somewhere that when you tighten the 
6 screws that hold the diaphram you are supposed to do this with the 
actuating lever pushed in a certain amount and that VW had a special 
took to help do this. I had always assumed that you were just 
supposed to do this with the diaphram in the center of its normal 
travel, but when I started checking my manuals, the only info I could 
find was that the limits on the stroke of the pushrod: 8 mm & 13 mm.

>From this, I guessed that the diaphram should be adjusted with the 
pushrod up halfway, or 10.5 mm.

I've now gone thru all my aftermarket manuals and the closest I can 
come to verifying this is the Haynes manual where it says to tighten 
those screws with the lever held in mid-stroke.

However, something just seems wrong about this. If we tighten the 
diaphram in mid stroke, then it seems like that won't leave it any 
slack for travel in either direction. In fact, Dan's old diaphram was 
hard, but it was bulged up between the outer rim and the center disk, 
and the new diaphram seemed like the bolt holes were in a circle just 
a tiny bit too large.

Okay, I'll check one last place. I've got a genuine VW workshop 
manual for the 1200 engine, but I don't know if this adjustment would 
have changed for the 1500/1600 engine. In that manual, it says adjust 
the gaskets to give a stroke between 8 mm & 13 mm. So far, so good; 
it describes the SAME stroke limits. Now, for the final answer: It 
says to tighten the diaphram with the lever depressed 14 mm and 
mentions the special gauge (VW 328d) that makes this easy.

So here's my question: Is this the same for the later engines? 

Russ, did you use the same setting jig (VW 328d) for the 40 hp and 53 
hp engines?

If so, then I guess the way to do this is to figure out which gaskets 
to use, remove 2-3 gaskets, tighten the diaphram, reinstall the 
gaskets and tighten down the pump.

Does this sound right?

I guess I'm just puzzled because this seems to be turning out 
differently from what I expected, but I have to admit that it makes 
more sense this way. It also means the Haynes manual is wrong.

Jim Adney, jadney@vwtype3.org
Madison, Wisconsin, USA

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