Volkswagen Cars 2000-05

Injection Pump

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Removal & Installation




NOTE
Special tools are required for injection pump installation. Do not remove the pump without these tools on hand.

  1. Disconnect the negative battery cable and remove the air cleaner, cylinder head cover and timing belt cover.
  2.  
  3. Turn the engine to TDC of No. 1 cylinder and insert a setting bar into the slot on the rear of the camshaft, VW tool 2065A or equivalent, to hold the camshaft in place. Remove the timing belt. Be careful to not turn the engine while the belt is removed.
  4.  



Click image to see an enlarged view

Fig. Install the bar to hold the camshaft in position during Diesel injection pump service

  1. Loosen the pump drive sprocket nut but don't remove it yet. Install a puller on the sprocket and apply moderate tension.
  2.  
  3. Rap the puller bolt with light hammer taps until the sprocket jumps off the tapered shaft, then remove the puller and sprocket. Be careful not to lose the Woodruff key.
  4.  
  5. Hold the pump fittings with a wrench and using a line wrench, remove the injection lines from the pump. Cap the pump fittings to keep dirt out. It may be easier to remove the lines from the injectors also and set them aside as an assembly. Cap the injector fittings to keep dirt out.
  6.  
  7. Disconnect the control cables, fuel solenoid wire and fuel supply and return lines.
  8.  
  9. Remove the pump mounting bolts and lift the pump from the vehicle.
  10.  

To install:

  1. When reinstalling, align the marks on the top of the mounting flange and the pump and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the Woodruff key and sprocket and tighten the nut to 33 ft. lbs. (45 Nm).
  4.  
  5. When reinstalling the supply and return lines, be sure the fitting marked OUT is used for the return line. This fitting has an orifice and must be in the correct place. Use new gaskets.
  6.  
  7. Turn the pump sprocket so the mark aligns with the mark on the side of the mounting flange and insert a pin through the hole in the sprocket to hold it in place.
  8.  
  9. Install the camshaft drive sprocket and belt and set the belt tension. Tension the drive belt by turning the tensioner pulley clockwise until the belt can be flexed 1 / 2 in. (13mm) between the camshaft and the pump sprockets. Remove the pin.
  10.  
  11. Remove the camshaft holding bar. Turn the engine through 2 full turns, return to TDC of the No. 1 cylinder and recheck the belt tension and camshaft timing.
  12.  
  13. Reinstall the injection lines, wiring and control cables. Tighten the line nuts to 18 ft. lbs. (25 Nm).
  14.  

Alh Engines

NOTE
Special tools are required for injection pump installation. Do not remove the pump without these tools on hand.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Timing belt from camshaft and injection pump sprockets
     

  4.  


NOTE
The vibration damper and center and lower timing belt covers can remained installed.



Fuel lines at fuel pump
 
Adjuster connector from retainer
 
Injection pump sprocket bolts
 


NOTE
DO NOT loosen the pump sprocket center bolt or the basic pump setting will be disturbed.



Compact bracket bolts
 
Injection pump rear support bolt
 
Injection pump
 

To install:

  1. Install the injection pump into the compact bracket, then tighten the rear support bolt first.
  2.  
  3. Insert the front bolts and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the injection pump sprocket to the hub and lightly tighten the bolts.
  6.  
  7. Lock the injection pump sprocket with holding tool 3359.
  8.  
  9. Align the elongated holes of the sprocket install the timing belt and tighten the sprocket bolts to 15 ft. lbs. (20 Nm) plus 90°.
  10.  
  11. The remainder of the installation is the reverse of the removal procedures, noting the following torque specifications:
    1. Tighten the injector lines to 18 ft. lbs. (25 Nm).
    2.  
    3. Tighten the fuel line fittings to 18 ft. lbs. (25 Nm).
    4.  
    5. Tighten the pressure line union to 33 ft. lbs. (45 Nm).
    6.  
    7. Tighten the compact bracket bolts to 18 ft. lbs. (25 Nm)
    8.  

  12.  


    Click image to see an enlarged view

    Fig. Exploded view of injection pump assembly-1.9L ALH engine



NOTE
Special tools are required for injection pump installation. Do not remove the pump without these tools on hand.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:
    NOTE
    The vibration damper and center and lower timing belt covers can remained installed.


    NOTE
    DO NOT loosen the pump sprocket center bolt or the basic pump setting will be disturbed.



    Negative battery cable
     
    Timing belt from camshaft and injection pump sprockets
     



    Fuel lines at fuel pump
     
    Adjuster connector from retainer
     
    Injection pump sprocket bolts
     



    Compact bracket bolts
     
    Injection pump rear support bolt
     
    Injection pump
     

  4.  

To install:

  1. Install the injection pump into the compact bracket, then tighten the rear support bolt first.
  2.  
  3. Insert the front bolts and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the injection pump sprocket to the hub and lightly tighten the bolts.
  6.  
  7. Lock the injection pump sprocket with holding tool 3359.
  8.  
  9. Align the elongated holes of the sprocket install the timing belt and tighten the sprocket bolts to 15 ft. lbs. (20 Nm) plus 90°.
  10.  
  11. The remainder of the installation is the reverse of the removal procedures, noting the following torque specifications:
    1. Tighten the injector lines to 18 ft. lbs. (25 Nm).
    2.  
    3. Tighten the fuel line fittings to 18 ft. lbs. (25 Nm).
    4.  
    5. Tighten the pressure line union to 33 ft. lbs. (45 Nm).
    6.  
    7. Tighten the compact bracket bolts to 18 ft. lbs. (25 Nm)

      Click image to see an enlarged view

      Fig. Exploded view of injection pump assembly-1.9L ALH engine

    8.  

  12.  

Except Alh Engines

NOTE
Special tools are required for injection pump installation. Do not remove the pump without these tools on hand.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Air cleaner
     
    Cylinder head cover
     
    Timing belt cover.
     

  4.  
  5. Turn the engine to TDC of No. 1 cylinder and insert a setting bar into the slot on the rear of the camshaft, VW tool 2065A or equivalent, to hold the camshaft in place. Remove the timing belt. Be careful to not turn the engine while the belt is removed.
  6.  
  7. Loosen the pump drive sprocket nut but don't remove it yet. Install a puller on the sprocket and apply moderate tension.
  8.  
  9. Rap the puller bolt with light hammer taps until the sprocket jumps off the tapered shaft, then remove the puller and sprocket. Be careful not to lose the Woodruff key.
  10.  
  11. Hold the pump fittings with a wrench and using a line wrench, remove the injection lines from the pump. Cap the pump fittings to keep dirt out. It may be easier to remove the lines from the injectors also and set them aside as an assembly. Cap the injector fittings to keep dirt out.
  12.  
  13. Disconnect the control cables, fuel solenoid wire and fuel supply and return lines.
  14.  
  15. Remove the pump mounting bolts and lift the pump from the vehicle.
  16.  


    Click image to see an enlarged view

    Fig. Install the bar to hold the camshaft in position during diesel injection pump service


To install:

  1. When reinstalling, align the marks on the top of the mounting flange and the pump. Mounting bolts: 18 ft. lbs. (25 Nm).
  2.  
  3. Install the Woodruff key and sprocket. Nut: 33 ft. lbs. (45 Nm).
  4.  
  5. When reinstalling the supply and return lines, be sure the fitting marked OUT is used for the return line. This fitting has an orifice and must be in the correct place. Use new gaskets.
  6.  
  7. Turn the pump sprocket so the mark aligns with the mark on the side of the mounting flange and insert a pin through the hole in the sprocket to hold it in place.
  8.  
  9. Install the camshaft drive sprocket and belt and set the belt tension. Tension the drive belt by turning the tensioner pulley clockwise until the belt can be flexed12
  10.  
  11. Remove the camshaft holding bar. Turn the engine through 2 full turns, return to TDC of the No. 1 cylinder and recheck the belt tension and camshaft timing.
  12.  
  13. Reinstall the injection lines, wiring and control cables. Line nuts: 18 ft. lbs. (25 Nm).
  14.  


NOTE
Special tools are required for injection pump installation. Do not remove the pump without these tools on hand.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Air cleaner
     
    Cylinder head cover
     
    Timing belt cover.
     

  4.  
  5. Turn the engine to TDC of No. 1 cylinder and insert a setting bar into the slot on the rear of the camshaft, VW tool 2065A or equivalent, to hold the camshaft in place. Remove the timing belt. Be careful to not turn the engine while the belt is removed.

    Click image to see an enlarged view

    Fig. Install the bar to hold the camshaft in position during diesel injection pump service

  6.  
  7. Loosen the pump drive sprocket nut but don't remove it yet. Install a puller on the sprocket and apply moderate tension.
  8.  
  9. Rap the puller bolt with light hammer taps until the sprocket jumps off the tapered shaft, then remove the puller and sprocket. Be careful not to lose the Woodruff key.
  10.  
  11. Hold the pump fittings with a wrench and using a line wrench, remove the injection lines from the pump. Cap the pump fittings to keep dirt out. It may be easier to remove the lines from the injectors also and set them aside as an assembly. Cap the injector fittings to keep dirt out.
  12.  
  13. Disconnect the control cables, fuel solenoid wire and fuel supply and return lines.
  14.  
  15. Remove the pump mounting bolts and lift the pump from the vehicle.
  16.  

To install:

  1. When reinstalling, align the marks on the top of the mounting flange and the pump. Mounting bolts: 18 ft. lbs. (25 Nm).
  2.  
  3. Install the Woodruff key and sprocket. Nut: 33 ft. lbs. (45 Nm).
  4.  
  5. When reinstalling the supply and return lines, be sure the fitting marked OUT is used for the return line. This fitting has an orifice and must be in the correct place. Use new gaskets.
  6.  
  7. Turn the pump sprocket so the mark aligns with the mark on the side of the mounting flange and insert a pin through the hole in the sprocket to hold it in place.
  8.  
  9. Install the camshaft drive sprocket and belt and set the belt tension. Tension the drive belt by turning the tensioner pulley clockwise until the belt can be flexed 1 / 2 in. (13mm) between the camshaft and the pump sprockets. Remove the pin.
  10.  
  11. Remove the camshaft holding bar. Turn the engine through 2 full turns, return to TDC of the No. 1 cylinder and recheck the belt tension and camshaft timing.
  12.  
  13. Reinstall the injection lines, wiring and control cables. Line nuts: 18 ft. lbs. (25 Nm).
  14.  

 
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