Injection pump, removing and installing: Removing

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.

Remove engine cover.

Fig 1: Fuel Supply And Return Lines At Injection Pump

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Disconnect fuel supply and return lines at injection pump - arrows -.
Seal lines so that fuel system is not contaminated by dirt etc.
Remove injector lines using Injector Line Wrench 3035.

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.

Remove cylinder head cover.
Remove vacuum pump for brake servo.

Engine installed:

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

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Turn crankshaft to TDC on No.1 cylinder (vehicles with manual transmission).

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

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Set crankshaft to TDC on No.1 cylinder (vehicles with automatic transmission).

Engine removed:

Vehicles with manual transmission

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

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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

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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

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Lock camshaft with setting bar 3418.
Centralize setting bar as follows:
Turn camshaft so that one end of setting bar contacts cylinder head.
Using feeler gauge establish gap at other end of setting bar.

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

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Lock injection pump sprocket using Rig Pin 3359.
Remove injection pump sprocket bolts - 1 -.

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.

Remove tensioning roller nut.
Relieve toothed belt tension and remove camshaft and injection pump sprockets.

Fig 8: Fuel Injection Pump

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

Fig 9: Compact Bracket Securing Bolts

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Remove securing bolts from compact bracket - 1 -.

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

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Remove bolt from rear support - arrow -.
Remove injection pump.