Fuel Injection Pump: Removal
- If injection pump is faulty, it must be replaced. Special test equipment and service tools are necessary for making repairs. For Audi Vehicles, continue to step 2). For Volkswagen vehicles, proceed to step 3.
- For Audi vehicles, remove vacuum pump pulley, and drive belt and injection pump drive belt cover. Set crankshaft at TDC for No. 1 cylinder. Align marks on flywheel and clutch housing, and injection pump sprocket and mounting plate. Install special setting pin (2064) to lock injection pump driven sprocket securely. See Fig 1. Lock vacuum pump belt pulley and injection pump drive sprocket with special pulley locking tool (3036). See Fig 1. Loosen and remove retaining bolt and remove drive sprocket and drive belt. Proceed to step 4.
Audi pulley identification and tool location.
Volkswagen models only.
- For Volkswagen vehicles, turn engine to TDC on No. 1 cylinder. Lock camshaft with special setting bar (2065 or 2065-A). See Fig 2. Remove drive belt. Proceed to step 4).
- Loosen injection pump driven sprocket retaining nut approximately one turn. On Audi vehicles, remove special setting pin (2064) from pump driven sprocket.
- Attach puller (VW203B for Volkswagen; 3032 for Audi) to injection pump sprocket and apply light tension to puller. See Fig 3. Tap lightly on puller spindle head until sprocket loosens from pump shaft.
Audi models shown, Volkswagen similar.
- Remove puller and nut and remove sprocket by hand. Disconnect all fuel pipes from pump. Cover unions with clean cloth. Disconnect wire from fuel shut-off solenoid and detach accelerator cable. On Turbo Diesel models, remove boost pressure intake line from boost pressure enrichment device on injection pump. Support injection pump and remove pump mounting bolts. Carefully remove pump.