[Vwdiesel] Injection Pump Replacement This Weekend

[Val Christian]

Bryan,

I haven't followed your thread closely, but I'll give a few comments.

Sometimes you can pull the crank pulley without untensioning the AC.
Pull the four allen bolts.  I use air impact, with a mouse.  If you 
don't have that, try a strap wrench on the pulley, to somehow lock
it in place.  I just always use light air impact.  If you don't have 
impact, try tapping on a small breakerbar to loosen the bolts.

Then slide the pulley off the cogbelt pulley.  To put it back on,
you'll have to stretch it, as you'll be tightening the AC belt
as you pull the pulley over the center hub.  Slip one of the four
bolts in (the one farthest from the AC works best).  The ledge
on the pulley, and the crank bolt will give you points to lever 
off of.  Don't undo that 12 point bolt.  You'll have more work
to do otherwise.

If the AC belt is tight, then you'll use screwdrivers, prybars and 
like ilk.

For loosening the 17mm AC retainer bolts...I use a combination of 
combo wrenches, crows foot wrenches and sockets.  The exact recipe 
depends on the particular car.  One of them I recall cramming a 1/4"
screwdriver against a nut and casting to hold it while I spun it's
partner.  Get the picture?  It's doable, just not in the text book.
The German's must have a really long term for whatever is involved.

Oh, on those allen head bolts...keep some spares.  If they are rusty,
and you haven't been pulling your pulley off much recently, you may 
mung the head.  The best thing then is to hammer in slightly larger 
tools you may have gotten in the same set of tools.  Like Torx head
tools.  This is what they were really made for, until someone invented
torx bolts.  In a pinch, going up a size might help.  One time I put 
braze material on the allen tool, and filed it down until it was very 
snug.

Copious penetrant gives you something else to blame for slipped tools
and skinned knuckles.

Use a hammer, and firmly tap the allen bit into the socket head prior
to attempting to turn it.  If using impact, limit the flow so that you
don't exceed about 35 ft lb.  Rock the direction back and forth, 
accepting small motion of the screw at first.  

Putting back together use neversieze.  I use flat washers as well.
Torque with the calibrated "brrapp" of the 3/8" impact mouse.
If you don't have one, about 15 to 20 ft lbs.

Good luck.

Val 





> Hi everybody,
> 	Its Friday night, about 10:41PM.  I'm calling it quits for the
> evening with regards to my IP swap on this rabbit.  I knew this would
> be a difficult project, but I didn't think I'd have difficulties this
> early in the process.  Argh.
> 	Unfortunately, my Rabbit has A/C (not working, yet still
> there.)  So, if I understand Bentley correctly, I need to at least
> loosen the tension on the A/C compressor tensioner in order to loosen
> the A/C belt so that I can remove the outer crankshaft pulley.  Is
> this correct?  I had no problems getting the alternator belt loose and
> the alternator out.  Do I really need to loosen the tension on the A/C
> compressor belt?  The reason I ask is that I can't get my 17mm wrench
> (or socket) in there to move the nuts.  I don't know how they were
> ever tightened up the last time.
> 	Also, regarding removing the four allen bolts holding the
> outer crankshaft pulley.  The second I try to loosen any of those
> bolts, the pulley spins.  Any suggestions here?
> 
> Thanks,
> Bryan
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