Injection pump, removing and installing: Removing

WARNING: This page is about a different variant/trim than selected.

Fig 1: Fuel Supply And Return Lines At Injection Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Always remove two-piece line set as a complete unit. Do not alter the shape of the lines.

Cover openings with a clean cloth.
Remove right headlight: → 94 LIGHTS, SWITCHES - EXTERIOR
Remove connecting line between charge air cooler and intake manifold. → 21 - TURBOCHARGER, G-CHARGER
Remove upper part of toothed belt guard.

Engine installed:

Fig 2: Identifying Crankshaft At TDC No. 1 Cylinder (Vehicles With A Manual Transmission)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig 3: Identifying Crankshaft At TDC No. 1 Cylinder (Vehicles With A Automatic Transmission)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine removed:

Vehicles with manual transmission

Fig 4: Identifying TDC Mark On The Flywheel Aligned With Tip Of Adjustment Gauge 2068 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install adjustment device 2068 A as shown.
Set adjustment device to 96 mm - arrow A -. Left-hand notch of vernier scale is reference point.
Turn crankshaft until flywheel TDC marking aligns with point of setting device - arrow B -.

Vehicles with automatic transmission

Fig 5: Identifying TDC Mark On The Crankshaft Aligned With Tip Of Adjustment Gauge 2068 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install adjustment device 2068 A as shown.
Set adjustment device to 30 mm - arrow A -. Left-hand notch of vernier scale is reference point.
Turn crankshaft until TDC marking on drive plate aligns with point of setting device - arrow B -.

Continued for all vehicles

Fig 6: Identifying Camshaft Secured Using Adjustment Guide 3418

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place a feeler gauge corresponding to one half of gap between setting bar and cylinder head.
Turn camshaft until setting bar contacts feeler gauge.
Place a 2nd feeler gauge, of same thickness, at the other end between setting bar and cylinder head.

Fig 7: Identifying Injection Pump Sprocket, Rig Pin 3359, Bolts & Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

DO NOT loosen the hub nut - 2 -. If nut - 2 - is loosened the injection pump basic setting will be altered and this cannot be reset with normal workshop equipment.

Fig 8: Fuel Injection Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 10-pin connector for injection pump metering unit - arrow - and release connector from retainer.

Fig 9: Compact Bracket Securing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

DO NOT loosen the hub nut - 2 -. If nut - 2 - is loosened the injection pump basic setting will be altered and this cannot be reset with normal workshop equipment.

Fig 10: Rear Support Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.