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2001 volkswagen beetle: diesel..1.9 tdi..The injector pump is leaking

Customer Question
I nave a 2001 volkswagon...
I nave a 2001 volkswagon beatle diesel 1.9 tdi engine. The injector pump is leaking. I found a rebuilt unit on line and my question is do I have to have special tools to replace it? Also is this something over my head. I am a backyard mech. Rick
Submitted: 7 years ago.Category: VW
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Answered in 12 minutes by:
9/15/2010
VW Mechanic: Drew, Super Mazda Tech replied 7 years ago
Drew
Drew, Super Mazda Tech
Category: VW
Satisfied Customers: 2,518
Experience: 17 yrs. experience as a shop owner with Ford, Linc. & Merc. experience. ASE L1 Advanced Certified Master Tech. and Mazda Certified.
Verified
This is a big job around 3.5 hours for and tech and requires special tools. May take longer if doing at home for the first time. There is a very lengthy procedure for this repair that involves removing the timing belt. If you want to tackle it I can send you the repair procedure.
Drew
Drew, Super Mazda Tech
Category: VW
Satisfied Customers: 2,518
Experience: 17 yrs. experience as a shop owner with Ford, Linc. & Merc. experience. ASE L1 Advanced Certified Master Tech. and Mazda Certified.
Verified
Drew and 87 other VW Specialists are ready to help you
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Customer reply replied 7 years ago
I need the procedure. Can you E-Mail it?
Customer reply replied 7 years ago
This is my first time doing this. Have I lost you ? Thanks Rick
VW Mechanic: Drew, Super Mazda Tech replied 7 years ago

Very sorry I wasn't able to get back to you. Just Answer put a lock on this question so I couldn't get you the procedure. I was able to have them reopen the question. SOrry for the delay and thanks for the tip!!Smile

 

Diesel Injection Pump, Removing and Installing

Special tools
graphic

  • 3098 Lever camber adjustment
  • V159 Pin wrench
  • 3359 Rig pin
  • VAG 1318/10 Adapter
  • 3418 Adjustment guide
  • VAG 1390 Hand vacuum pump
  • graphic
    • 2068A Adj. gauge TDC
    • 3035 Injector line wrench
    • VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb) or equivalent

    Diesel injection pump, removing

    WARNING!
    Fire hazard! Do NOT have anything in the area that can ignite Diesel fuel

    NOTE: Use 3035 tubing wrench to loosen the high pressure fuel lines.

    • Cover openings with a clean cloth.
    • Remove connecting line between charge air cooler and intake manifold.
    • Remove upper toothed belt guard and valve cover.
    • Remove vacuum pump for brake servo.
    • graphic
    • Turn crankshaft to cyl. 1 TDC -arrow-.
    • graphic
      • Turn crankshaft to cyl. 1 TDC -arrow-
      • for Automatic transmission

      With engine removed

      Vehicles with manual transmission

    • graphic

    •  

      • Install 2068 A TDC gauge as shown.
      • Set adjustment device to 96 mm -arrow A-.
      • Left-hand notch of the vernier scale is the reference point.
      • Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-.

      Vehicles with automatic transmission

    • graphic

    •  

      • Install 2068 A TDC gauge as shown.
      • Set adjustment device to 30 mm -arrow A-.
      • Left-hand notch of the vernier scale is the reference point.
      • Turn crankshaft until TDC marking on drive plate aligns with point of setting device - arrow B-.

      All vehicles

  • graphic

 

 

Lock camshaft with setting bar.

  • Centralize setting bar as follows: Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge, establish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of same thickness, at the other end between the setting bar and cylinder head.
  • graphic
    • Remove injection pump sprocket mounting bolts -1-.

    CAUTION!
    Do not loosen hub nut -2-for ANY reason. Otherwise, the Diesel injection pump basic setting will be altered and cannot be reset with normal workshop equipment.

    • Remove tensioning roller nut.
    • Relieve tooth belt tension then remove camshaft and injection pump sprockets.
    • Disconnect Quantity adjuster harness connector and unclip connector from retainer
    • graphic
    • Remove mounting bolts from assembly bracket -1-.
    • graphic
      • Remove bolt from rear support -arrow-
      • Remove Diesel injection pump.

      Diesel injection pump, installing

      • Insert injection pump into assembly bracket then tighten mounting bolt on rear support with conical nut first.
      • Insert front mounting bolts.
      • tighten to 25 Nm (18 ft lb)
      • graphic
        • Install new bolts -arrows- to mount injection pump sprocket to hub but do not tighten.
        • Align injection pump sprocket to central position in elongated holes.
        • Lock injection pump sprocket using 3359 pin.
        • Loosen camshaft sprocket mounting bolt a half turn.
    • graphic
    • Place a drift through hole in rear of toothed belt guard and release camshaft sprocket from camshaft taper with blow from hammer.
    • Remove camshaft sprocket.
    • Check whether TDC mark on flywheel and reference mark are aligned.
    • Place tooth belt on injection pump sprocket and tensioning roller.
    • Install camshaft sprocket into toothed belt and secure sprocket such that the camshaft can still turn
    • graphic
    • Tension toothed belt using pin wrench (e.g. Matra V159) on eccentric and turning clockwise until notch and raised mark align -arrows
    • graphic
    • NOTE: Make sure retaining hook is correctly seated in toothed belt guard.

      • Tighten mounting nut.
      • 20 Nm (15 ft lb)
      • Check TDC mark on flywheel again.
      • Tighten new mounting bolts for injection pump sprocket.
      • 20 Nm (15 ft lb)

      NOTE:

      • After dynamically checking the injection timing, tighten the bolts an additional 1/4 turn (90 °) .
      • The mounting bolts (stretch design) may only be used once.
      • Tighten camshaft sprocket mounting bolt.
      • 45 Nm (33 ft lb)
      • Remove 3359 locking pin.
      • Remove 3418 setting bar from camshaft.
      • Turn crankshaft two rotations in direction of engine rotation until crankshaft is set to cyl. 1 TDC again.
      • Reconnect injection lines, fuel supply line and electrical wiring.
      • graphic
      • Fill injection pump with Diesel fuel as follows.
        • Screw 1318/10 adapter into injection pump return/supply opening.
        • Connect VAG 1390 hand vacuum pump to adapter using approx.40 inches of transparent plastic hose.
        • Operate vacuum pump until fuel flows out of return/supply opening.
        • Do not draw fuel into vacuum pump.
        • Remove adapter and connect return/supply line.
        • Install valve cover and vacuum pump.
        • Dynamically check Start of injection and adjust if necessary
Drew
Drew, Super Mazda Tech
Category: VW
Satisfied Customers: 2,518
Experience: 17 yrs. experience as a shop owner with Ford, Linc. & Merc. experience. ASE L1 Advanced Certified Master Tech. and Mazda Certified.
Verified
Drew and 87 other VW Specialists are ready to help you
Ask your own question now
Ask Drew Your Own Question
Drew
Drew
Drew, Super Mazda Tech
Category: VW
Satisfied Customers: 2,518
2,518 Satisfied Customers
Experience: 17 yrs. experience as a shop owner with Ford, Linc. & Merc. experience. ASE L1 Advanced Certified Master Tech. and Mazda Certified.

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