[Vwdiesel] Injection Pump Replacement This Weekend

Bryan K Walton bryankwalton at machlink.com
Thu Jan 4 09:05:27 EST 2007


Hi guys,
	A few weeks ago, I wrote to the mailing list about my leaking
injection pump.  Well, Friday night I'll be starting the process of
swapping out my pump with a remanufactured pump.  I'm a little
nervous (I've not tackled anything this complex on my Rabbit before). 
Hopefully all will go well.  I need to have the Rabbit ready to go for
Monday morning.  Here are the parts and tools I have ready.  

Tools:
Timing Belt Tensioner
Injection Pump Locking Pin
Camshaft Locking Plate
Dial Indicator for Pump Timing
Other standard tools (sockets wrenches, etc.)
Bentley Manual

Parts:
New timing belt
New timing belt tensioner pulley
Remanufactured pump
Valve Cover Gasket

Where I'm nervous is with regard to the process.  I'll follow the pump
removal steps in the Bentley manual step by step, starting with
removing the timing belt, then the pump.  Replacing the pump, and then
putting it all back together, timing the pump, and then priming it.
I'm going to be timing the pump for maximum mpg.

Question 1. I've read online that I need a puller to get the sprocket
off my old pump.  But I've also read that I can loosen the nut then give
the pulley a good sharp whack with a rubber hammer on the teeth of the 
pulley.  Comments?

Question 2. Are there any "gotchas" that the Bentley manual either
forgets to mention or is unclear about?  Steps not included?  Any
"tricks" that I should know about to help in this process?

Question 3. Any other special tools needed that I haven't mentioned?

Thanks!
Bryan


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