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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 ******************************* ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~