Vanagon L4-1588cc 1.6L DSL SOHC (1983)
Diesel MFI Pump: Service and Repair
Injection Pump Replacement
1.
Remove timing belt as outlined in ``Timing Belt, Replace.''
2.
Loosen injection pump sprocket retaining bolt slightly.
3.
Install puller VW203b or equivalent so that jaws are at 90° angle to crossbar and facing direction of spindle rotation.
4.
Carefully apply pressure to sprocket and tap puller spindle with a light hammer until sprocket is released from shaft taper. Do not apply excessive
force with puller, as sprocket will be damaged.
5.
Remove puller, retaining bolt and sprocket.
6.
Disconnect fuel lines from pump and plug lines and open fittings.
7.
Disconnect accelerator and cold start cable from pump, and wiring harness connector to fuel shut-off solenoid.
8.
Remove lower bolt securing pump mounting plate, bolts securing pump to mounting plate and braces (if equipped) and remove pump. Do not
loosen bolts on fuel distributor head, as distributor will be damaged.
9.
Install pump on mounting bracket with marks on pump and bracket aligned. Torque bolts to 18 ft. lbs.
10.
Install pump sprocket and torque retaining bolt to 33 ft. lbs. Align mark on pump sprocket with marks on pump and bracket and lock position with
pin 2064.
11.
Reverse procedure to complete installation. Install timing belt as outlined in ``Timing Belt, Replace,'' adjust cold start and accelerator cables, and
check injection timing.
