Diesel injection pump, removing and installing: Removing
WARNING: This page is about a different car, the 1996 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
- Set crankshaft to TDC for Cyl.1 (-arrow-) and lock camshaft and setting bar in place.
Center setting bar as follows:
- Turn locked camshaft, with setting bar in place, until one end of setting bar touches cylinder head.
- Measure gap at other end of setting bar with feeler gauge.
- Select feeler gauge that is one-half of measured gap, and temporarily install between setting bar and cylinder head. Turn camshaft so that setting bar is resting against feeler gauge, then insert second feeler gauge of same thickness at other end between setting bar and cylinder head.
- Remove toothed drive belt from camshaft sprocket and injection pump sprocket.
- Loosen securing nut for injection pump sprocket.
- Slacken puller and attach to pump sprocket. Align puller legs with holes in sprocket.
- Tighten puller to apply tension to pump sprocket.
- Loosen injection pump sprocket from tapered pump shaft by tapping lightly on puller's center spindle -arrow- (hold tightly during this step so sprocket does not fall).
- Disconnect all fuel lines at injection pump and cover over openings with clean cloths.NOTE: Use injector line wrench 3035 to disconnect lines.
- Disconnect cable from stop control.
- Detach accelerator and cold start accelerator cables.
- Remove three mounting bolts from bracket -2-.
- Remove mounting bolts from rear support -1-.
CAUTION: DO NOT loosen the bolts holding the pump. Loosening these bolts allows the pump head to move, which causes the fuel distributor plunger to fracture.