Injection pump, removing and installing: Installing

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

Insert injection pump into compact bracket 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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install injection pump sprocket to hub with securing bolts - arrows - but do not tighten.
When doing this, observe the different versions of injection pump sprocket securing bolts: Types of injection pump sprocket securing bolts .
Lock injection pump sprocket with 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 with counter-hold tool 3036 and loosen camshaft bolt by 1 turn.

NOTE:

Never use camshaft bar T10098 as a counter-hold when loosening and tightening the camshaft sprocket. Use counter-hold tool 3036.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place puller T40001 with single leg T40001 /2 - A - and double leg T40001 /3 - B - centrally on the camshaft sprocket and pull it off.

Use an open ended wrench - C - to counter-hold when doing this.

Remove camshaft sprocket.
Check whether TDC mark on flywheel and reference mark are aligned.
Place tooth belt on injection pump sprocket and tensioning roller.
Fit camshaft sprocket into toothed belt and secure sprocket so that the camshaft can still turn.

Fig 4: V.A.G 1318/10 & V.A.G 1390

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fill injection pump with Diesel as follows.

Thread adapter VAG1318/10 into return hole in injection pump.
Connect hand vacuum pump VAG1390 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.

Dynamically check start of injection and adjust if necessary → Start of injection, dynamically checking and adjusting .