Diesel injection pump, removing and installing: Removing
WARNING: This page is about a different car, the 1999 Volkswagen Jetta, 1998 Volkswagen Jetta, and 1997 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
- Remove air cleaner and upper toothed belt guard.
- Remove cylinder head cover.
- Rotate crankshaft to TDC for cylinder 1 (arrow).
- Lock camshaft with 2065A setting bar.
- Position camshaft with 2065A setting bar as follows:
- Turn camshaft until one end of bar contacts cylinder head, then use feeler gauge to measure gap at other end of bar.
- Place another feeler gauge (thickness = 1/2 measured gap) between setting bar and cylinder head.
- Turn camshaft until setting bar contacts feeler gauge, then place another feeler gauge of equal thickness at other side, between setting bar and cylinder head.
- Remove idler roller, remove nut from tensioner roller, and release tension of toothed drive belt.
- Remove belt from sprockets, and lock Diesel injection pump sprocket in position using lock pin 2064.
- Remove injection pump sprocket mounting nut.
- Loosen arms of 3032 puller, place arms in position through holes in injection pump sprocket, and tighten.
- Place injection pump sprocket under tension with puller.
- Hold onto sprocket and tap lightly on puller spindle to release sprocket from injection pump tapered shaft (arrow).
- Unbolt all fuel lines at fuel pumpNOTE: Use 3035 tubing wrench to remove high pressure fuel lines.
- Cover openings with clean lint free cloth
- Disconnect fuel cut -off valve/cold start injector connector.
- Disconnect quantity adjuster harness connector and unclip connector retainer.
- Remove mounting bolts from bracket -arrows-
- Remove bolt from rear support (arrow).
- Remove Diesel injection pump.