[Vwdiesel] Injection Pump Replacement This Weekend

[Rudy]

Bryan,

The steps in the Bentley are pretty straight forward, I can't remember the
steps offhand but just make sure the timing mark on the Flywheel is lined up
and the Cam is on or close to Top Dead Center for No. 1 Piston BEFORE you
remove the old belt and you'll be good to go.

Take your time and use the Book step by step.  This group is pretty quick to
respond if you have a question along the way, if you can't get a response
fast enough out of the forum you may feel free to call me and I'll help if I
can, I'm in Seattle.  Good luck.

Rudy
206-790-8570 

-----Original Message-----
From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com] On
Behalf Of Bryan K Walton
Sent: Thursday, January 04, 2007 6:05 AM
To: VW Diesel Fans
Subject: [Vwdiesel] Injection Pump Replacement This Weekend

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
_______________________________________________
Vwdiesel mailing list
Vwdiesel at vwfans.com
http://www.audifans.com/mailman/listinfo/vwdiesel