Removal and installation of injection pump

To remove, disconnect the cable from the negative battery terminal. Remove the manhole cover at the top of the clutch housing. Rotate the crankshaft until the mark on the flywheel aligns with the mounting lug in the hatch of the clutch housing (pic. 3-18), which corresponds to the TDC of the compression stroke of the 1st cylinder, counting from the camshaft drive side. Remove cylinder head cover. Using the VW 20 65A retainer. which can also be made according to the dimensions shown in Fig. 3-19, block the camshaft as follows:

• insert the edge of the retainer into the groove of the rear flange of the camshaft;
• turn the camshaft until one of the ends of the retainer touches the surface of the cylinder head;
• measure the gap between the surface of the cylinder head and the other end of the retainer;
• place a gasket under both ends of the retainer with a thickness equal to half of the measured gap between the surface of the cylinder head and the end of the retainer. The total thickness of the two gaskets must be equal to the measured gap.

Remove the upper front toothed belt guard, loosen the toothed belt tension and remove it from the camshaft pulleys and injection pump. Loosen the nut securing the gear pulley of the injection pump drive.

Install the puller on the toothed pulley of the injection pump drive (pic. 3-36). Press the pulley off the injection pump drive shaft. hitting the pulley with an aluminum-faced hammer. Remove puller. Remove the pulley mounting nut, then remove the pulley. Disconnect the wires from the stop solenoid valve. Disconnect the fuel injection and starter control cables from the injection pump. On engines «RA», «SB», «AAZ» Disconnect the vacuum hose from the boost pressure corrector. Disconnect the high pressure fuel lines from the injectors and injection pump. plug the openings of the fuel lines and injection pump. Loosen the bolts securing the injection pump to the bracket and remove the injection pump. To install, put the injection pump on the bracket. aligning the alignment marks on the injection pump housing and the rear protective cover of the toothed belt. Tighten the injection pump mounting bolts. Make sure that there is a key in the groove of the injection pump drive shaft, install the gear pulley of the injection pump drive, screw on the fastening nut and turn the pulley until the marks on the pulley and the injection pump housing are aligned (pic. 3-20). Block the toothed pulley of the injection pump drive with a lock VW 20 64 (pic. 3-37) and tighten the pulley nut. Loosen the camshaft pulley mounting bolt half a turn and separate the pulley from the cone by hitting a hammer with a rubber striker (engines «1Y», «RA», «SB») or by hitting a drift inserted into the hole in the rear toothed belt guard (engine «AAZ»). Make sure that the mark on the flywheel corresponding to the TDC of the piston of the 1st cylinder is exactly aligned with the mark on the clutch housing. Put a toothed belt on the pulleys, remove the retainer and adjust the tension of the toothed belt using the VW 210 tool, as indicated in the subsection «Removing and installing the camshaft drive belt». Tighten the camshaft sprocket bolt to 4.5 kgf·m. Rotate the crankshaft two turns and check the toothed belt tension again. Adjust the fuel injection advance angle as shown below. Connect the fuel lines to the injectors and injection pump.






Warning. The fittings for fastening the supply and drain fuel lines to the injection pump have the same dimensions, but it is forbidden to interchange them, because the drain fuel line fitting with the inscription «OUT» (pic. 3-38) has a ball check valve.



Connect the stop solenoid connector.

Connect the fuel injection and starting control cables to the injection pump. On engines «RA», «SB», «AAZ» connect the vacuum hose to the boost pressure corrector. Install the front toothed belt guard. Remove the camshaft retainer. Install the cylinder head cover.

Connect the wire to the negative terminal of the battery.