Injection pump, removing and installing: Removing: Notes

• Remove engine cover.
• Disconnect fuel supply and return lines at injection pump (arrows).
Fig 1: Disconnecting Fuel Supply And Return Lines At Injection Pump
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• Seal lines so that fuel system is not contaminated by dirt etc.
• Remove injector lines with tool 3035.
  NOTE: Always remove two-piece line set as a complete unit. Do not alter the shape of the lines.
• Cover openings with a clean cloth.
• Remove right headlight:

  See LIGHTS, SWITCHES - EXTERIOR (FROM LATE PRODUCTION 1999)

• Remove connecting line between charge air cooler and intake manifold.

  See TURBOCHARGER, G-CHARGER - 1.9L 4CYL. 2V TDI - ALH

• Remove upper part of toothed belt guard.
• Remove cylinder head cover.
• Remove vacuum pump for brake servo.

Engine installed:

• Turn crankshaft to TDC on No. 1 cylinder (vehicles with manual transmission).
Fig 2: Identifying Turn Crankshaft To TDC On No. 1 Cylinder (Vehicles With Manual Transmission)
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• Set crankshaft to TDC on No. 1 cylinder (vehicles with automatic transmission).
Fig 3: Identifying Set Crankshaft To TDC On No. 1 Cylinder (Vehicles With Automatic Transmission)
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Engine removed: