Removing and installing injection pump — VW

🧭 Before you start

Set TDC with bar 2068 A and lock the camshaft with 2065 A, support the engine and remove the mounting and lock carrier. Release the belt, lock and pull the pump sprocket, disconnect lines and connector and unbolt the pump. On refit, centre the pump in its slots, set the sprocket nut to 55 Nm, re-time the camshaft sprocket, tension the belt (roller 20 Nm, camshaft bolt 45 Nm), turn the engine twice and recheck. Prime the pump through the return union with a hand vacuum pump, refit the mountings and check start of injection.

Fits: platform code 6N1

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: feeler gauge

Don't miss

• Never use adjustment bar 2065 A as a counterhold for the camshaft sprocket bolt; use counterhold 3036.
• Do not reshape the injection pipes; release them with ring spanner 3035.
• Notch and protrusion on the tensioner must face each other; if overshot, release fully and start again.
• Fill the pump through the return opening until fuel flows, but do not draw fuel into the vacuum pump.
• Expansion bolts on the engine mounting must not be reused.
• Start of injection is set dynamically with a diagnostic tester after assembly.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Remove filter/inlet connection connecting hose.
2. Remove upper toothed belt guard and cylinder head cover.
3. Turn crankshaft to TDC No. 1 cylinder (arrow).
4. Install TDC adjustment bar2068 A as shown.
5. Set TDC adjustment bar2068 A to 13.0 mm. The left notch of the vernier scale (arrow A) is the reference point.

6. Turn crankshaft until flywheel TDC marking aligns with point of adjustment bar (arrow B).
7. Lock camshaft with adjustment bar2065 A.
8. Align adjustment bar2065 A as follows: Turn locked camshaft until one end of the adjustment bar2065 A contacts cylinder head. Measure clearance which has arisen at other end of adjustment bar2065 A with a feeler gauge. Slide a feeler gauge with half of clearance dimension between adjustment bar2065 A and cylinder head. Now turn camshaft until adjustment bar2065 A contacts feeler gauge. Now insert a second feeler gauge with the same dimension between adjustment bar2065 A and cylinder head at other end.
9. Assemble and install support bracket10 - 222 A with frame10 - 222 A /1.
10. Insert support bracket into lifting eye on left cylinder head and raise engine slightly.
11. Remove bolts from engine assembly mounting (arrows) and remove complete assembly mounting.
12. Remove lock carrier with attaching parts: General body repairs, exterior50Removing and installing lock carrier with attaching parts. [Note: Do not detach the coolant hoses.]
13. Place lock carrier on the left longitudinal member and a suitable object, e.g. bucket. If necessary, secure lock carrier to prevent slipping off.
14. Remove guide roller.
15. Loosen nuts on belt tensioner (arrow).
16. Remove bracket from cylinder block.
17. Remove toothed belt from camshaft and injection pump toothed belt sprockets.
18. Lock injection pump sprocket with locking pin2064.
19. Unscrew injection pump sprocket securing nut.
20. Loosen puller3032 arms and position puller3032.
21. Align arms with bores on injection pump sprocket and tighten.
22. Tension injection pump sprocket with puller3032.
23. By tapping lightly on spindle of puller3032(arrow), loosen injection pump sprocket from injection pump taper (hold sprocket to prevent it from falling down).
24. Unscrew all fuel lines from pump. [Note: Use ring spanner3035 to release injection pipes.Do not alter shape.]
25. Cover openings with a clean cloth.
26. Disconnect 10-pin injection pump connector and unclip connector from retainer.
27. Unscrew securing bolts and nuts from console (arrows).
28. Then remove securing bolt from rear support (arrow).
29. Take off injection pump.
30. Insert injection pump into console and then tighten securing bolt on rear support with conical nut first.
31. Align injection pump to central position in console elongated holes and secure hand-tight. [Note: Commencement of injection is set dynamically using fault readerV.A.G 1551.]
32. Install injection pump sprocket and lock with locking pin2064. When installing observe spring washer seating.
33. Tighten securing nut to 55 Nm. — 55 Nm (41 lb-ft)
34. Loosen securing bolt of camshaft sprocket half a turn. To loosen securing bolt of camshaft sprocket, secure with counterhold3036. [Note: To loosen and tighten camshaft sprocket, never use adjustment bar2065 A as a counterhold! Use counterhold3036.]
35. Release camshaft pulley from taper on camshaft by striking on punch (positioned through hole in toothed belt guard) with in a blow from a hammer.
36. Take off camshaft sprocket.
37. Check whether TDC mark on flywheel and reference mark are aligned.
38. Place tooth belt on injection pump pulley and tensioning roller.
39. Fit camshaft sprocket into toothed belt and secure sprocket to camshaft so that the sprocket can still turn.
40. Install guide roller. Specified torque: 25 Nm. — 25 Nm (18 lb-ft)
41. Remove locking pin2064 from injection pump sprocket.
42. Turn belt tensioner to right with pin wrench3387 until notch and protrusion (arrows) are positioned opposite each other. [Note: If eccentric has been turned too far, tensioning roller must be completely relieved of tension and retensioned again. The eccentric should not be turned back just the amount it was turned too far.]
43. Tighten clamping nut on tensioning roller. Specified torque: 20 Nm — 20 Nm (15 lb-ft)
44. Again check whether TDC mark on flywheel and reference mark are aligned.
45. Tighten camshaft sprocket securing bolt. Specified torque: 45 Nm — 45 Nm (33 lb-ft)
46. Remove adjustment bar2065 A from camshaft.
47. Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
48. Check if the
49. If notch and protrusion are not located opposite each other, retension belt tensioner. To do this, hold belt tensioner with pin wrench3387, loosen securing nut, continue turning eccentric clockwise until notch and protrusion are located opposite each other and tighten securing nut to 20 Nm. — 20 Nm (15 lb-ft)
50. Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
51. Repeat check.
52. Connect injection pipes, fuel supply line and electrical lines.
53. Screw adapter setV.A.G 1318/10-12 into injection pump return aperture.
54. Connect hand vacuum pump with accessoriesV.A.G 1390/ to adapter with approx. 1 m transparent plastic hose.
55. Operate vacuum pump until fuel flows out of return aperture. Do not draw fuel into vacuum pump.
56. Remove adapter and connect fuel return line.
57. Fit engine mounting bracket to cylinder block. Specified torque: 45 Nm — 45 Nm (33 lb-ft)
58. Install engine assembly mounting. [Note: Expansion bolts must not be reused.]
59. Install toothed belt guard, cylinder head cover and connecting hose.
60. Install lock carrier with attaching parts: General body repairs, exterior50Removing and installing lock carrier with attaching parts.

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