REMOVAL & INSTALLATION
See Figure 1
Read through this entire procedure before proceeding. Special tools are required for injection pump installation. Do not remove the pump without these tools on hand.
- Disconnect the negative battery cable and remove the air cleaner, cylinder head cover and timing belt cover.
- 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.
- Loosen the pump drive sprocket nut but don't remove it yet. Install a puller on the sprocket and apply moderate tension.
- 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.
- 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.
- Disconnect the control cables, fuel solenoid wire and fuel supply and return lines.
- Remove the pump mounting bolts and lift the pump from the vehicle.
- When reinstalling, align the marks on the top of the mounting flange and the pump and torque the mounting bolts to 18 ft. lbs. (25 Nm).
- Install the Woodruff key and sprocket and torque the nut to 33 ft. lbs. (45 Nm).
- 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.
- 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.
- Install the camshaft drive sprocket and belt and set the belt tension. Tension the drive belt by turning the tensioner pulley clockwise until belt can be flexed 1 / 2 in. (13mm) between the camshaft and the pump sprockets. Remove the pin.
- Remove the camshaft holding bar. Turn the engine through 2 full turns, return to TDC of No. 1 cylinder and recheck the belt tension and camshaft timing.
- Reinstall the injection lines, wiring and control cables. Torque the line nuts to 18 ft. lbs. (25 Nm).
- Connect the battery cable.
The ball pin on the pump lever should be pointing up and be aligned with the mark in the slot. The accelerator cable should be attached at the upper hole in the bracket. With the pedal in the full throttle position, adjust the cable so that the pump lever contacts the stop without any binding or strain.Cold Start Cable
See Figure 2
When the cold start knob on the dash is pulled out, the fuel injection pump timing is advanced 2.5 degrees. This improves cold starting and running until the engine warms up.
- Insert the washer on the cable.
- Insert the cable in the bracket with the rubber bushing. Install the cable in the pin.
- Install the lockwasher.
- Move the lever to the zero position (direction of arrow). Pull the inner cable taut and tighten the clamp screw.
INJECTION PUMP TIMING
See Figure 3
- Turn the engine to TDC of the No. 1 cylinder.
- Make sure the pump control lever is fully against the low idle stop. If equipped with a manual cold start knob, make sure the knob is all the way in against the stop.
- Remove the center plug on the pump head, then install tool VW 2066 or an equivalent adaptor tool, and a dial indicator. Preload the dial indicator to 2.5mm.
- Slowly turn the engine counterclockwise until the dial gauge stops moving, then zero the dial indicator. This is the bottom of the pump stroke.
- Turn the engine clockwise until the TDC mark on the flywheel aligns with the pointer on the bell housing.
- The dial indicator should read 0.036-0.038 in. (0.90-0.95mm) for diesel engines or 0.038-0.040 in. (0.95-1.00mm) for turbo-diesel engines.
- If adjustment is required, remove the timing belt cover and loosen the pump mounting bolts without turning the engine.
- Turn the pump body until the dial indicator reads the correct value.
- Torque the mounting bolts to 18 ft. lbs. (25 Nm) and turn the engine backwards about 1 turn. Turn the engine forwards to TDC of No. 1 cylinder and recheck the dial indicator.
- When the correct setting is reached on the dial indicator, reinstall the belt cover and the center plug on the pump. Use a new copper gasket.