Removing 300 TDI injector pump

[Bazzle218]

I will be removing the injector pump in my beast in the next few days ( for repairs). I have the rave cd and it describes how to remove it without stripping the timing belt components down. My question they mention a special tool / Plate unfortunatley I dont have one. Can it be done without this plate or is Strip the timing cover off joby

[langy]

It would be better to go the long way and remove the timing cover and de-tension the timing belt and pulleys. That way you can inspect the area and attend to any unseen problems.

Whilst the tool has been described, it has not been pictured. I can only imagine that it is just a plate to fit the timing cover, and a drift to eject the pump and support the timing gear. But it would be under tension and that could be difficult to get force onto it without damaging something else.

Provided the crank nose hasn't been interfered with, getting the timing cover off isn't too hard. Mark which bolts go where on removal, think about using a washer on the crank pulley bolt to ensure correct torque on reassembly, and everything should be fine.

ps: Put a piece of cardboard or ply in front of the radiator - I made the mistake of not protecting it and slipped and put a hole in mine once.

[roverrescue]

Although I dont disagree with Langy that pulling the cover to give the rubber band a once over if you do want to just pop the pump off see here:

http://www.aulro.com/afvb/projects-tutorials/55098-300tdi-injection-pump-retaining-tool-lrt-12-045-a.html

I had just rebuilt a 300tdi (all new front end junk) and then on test run the IP was leaking... had a known good pump in shed so built up the LR tool figuring the timing belt etc etc was all A OK.

All went well, you can still check for timing with the cover on after re-installing the rebuilt pump without pulling the front off.

Steve

[langy]

A thousand pardons...

But a serious question: The plate holds the pulley nice and tight? And the pump just slides back in?

[roverrescue]

Once you remove the pump/pulley retaining plate, and essentially replace it with the "tool" the IP pulley is now clamped to the inside of the timing cover and cannot move.
Pump just slides out from the back (once you remove bits and bobs). I left the drill bit in the pump itself (it locks between pump body and rotor).

Everything is held at TDC whilst pump is removed.

just reread that and it is garbled... how about

serious answer: Yes and Yes

S