Injection pump, removing and installing: Installing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2001 Volkswagen Jetta, 2001 Volkswagen Golf, 2000 Volkswagen Jetta, 2000 Volkswagen Golf, and 1999 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Insert injection pump into compact bracket and then tighten securing bolt on rear support using conical nut first.
Insert front securing bolts and tighten to 25 Nm.

Fig 1: Injection Pump Sprocket To Hub Bolts & Rig Pin 3359

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Install injection pump sprocket to hub with new bolts - arrows - but do not tighten.
Lock injection pump sprocket using Rig Pin 3359.
Align injection pump sprocket to central position in elongated holes.

Fig 2: Holding Camshaft Sprocket Using Retainer 3036

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hold camshaft sprocket using Retainer 3036 and loosen camshaft bolt by 1 turn.

NOTE:

The Adjustment Guide 3418 must not be used as a counter-hold tool when loosening and tightening the securing bolt. The camshaft sprocket must always be held using Retainer 3036 when loosening or tightening the camshaft bolt.

Fig 3: Puller T40001, Single Arm Hook, Two-Arm Hook & Open End Wrench

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Position Puller T40001 with single arm hook - A - and two-arm hook - B - centralized on camshaft sprocket. Counter-hold on puller with open end wrench - C - and pull sprocket off.
Check whether TDC mark on flywheel and reference mark are aligned.
Place toothed belt on injection pump sprocket and tensioning roller.
Install camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still turn).

Vehicles with manual transmission

Fig 4: Tensioning Toothed Belt Using Two-Hole Pin Spanner

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Tension toothed belt using two-hole pin spanner on eccentric turning clockwise until notch and raised mark align - arrows -.

NOTE:

If necessary use a mirror for a visual check.

Vehicles with automatic transmission

Fig 5: Tensioning Toothed Belt By Turning Eccentric Clockwise Using A Commercially Available Hexagon Key

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Tension toothed belt by turning eccentric clockwise using a commercially available hexagon key until notch and indicator align.

NOTE:

If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must never be turned back when it has been turned too far.

Continued for all vehicles

Fig 6: Identifying Rear Toothed Belt Guard

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NOTE:

Make sure that the tensioning roller seats correctly in the rear toothed belt guard - arrow -.

Tighten lock nut on tensioning roller.

Tightening torque: 20 Nm

Check TDC mark on flywheel again.
Tighten new securing bolts for injection pump sprocket.

Tightening torque: 20 Nm

NOTE:

After dynamically checking the start of injection, the bolts must be tightened a further ¹ / ₄ turn (90 ° ).
The securing bolts are stretch bolts and must only be used once.

Fig 7: Holding Camshaft Sprocket Using Retainer 3036

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hold camshaft sprocket using Retainer 3036 and tighten camshaft sprocket securing bolt.

Tightening torque: 45 Nm

Remove Rig Pin 3359.
Remove Adjustment Guide 3418 from camshaft.
Turn crankshaft two revolutions in direction of engine rotation until crankshaft is set to TDC on No. 1 cylinder again.
Reconnect injection lines, fuel supply line and electrical wiring.

Fig 8: V.A.G 1318/10 & V.A.G 1390

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Fill injection pump with Diesel fuel as follows:

Thread adapter V.A.G 1318/10 into return hole in injection pump.
Connect hand vacuum pump V.A.G 1390 to adapter with approx. 1 m transparent plastic hose.
Operate vacuum pump until fuel flows out of return supply opening. Do not draw fuel into vacuum pump.
Remove adapter and connect return supply line.

Install vacuum pump.

Tightening torque: 20 Nm

Install cylinder head cover.

Tightening torque: 10 Nm

Install upper part of toothed belt guard.
Dynamically check start of injection and adjust if necessary → Start of injection, dynamically checking and adjusting .