How-To: Replace a MKIV ALH Diesel Injection Pump without Changing the Timing Belt

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
my buddies auto jetta and manual golf, he was selling the jetta and wanted to keep the auto pump so i did a pump swap in his driveway 25 minutes start to finish including hammer modding the manual pump... totally uneccessary to remove the VC during a swap ... just establish tdc first and have the pump pin handy
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Northeastern Illinois
TDI
2003 Jetta GLS TDI 5-speed
Dumped Photobucket

As some of you probably know, Photobucket made a decision to require those of us that use them for pictures on forums like TDI Club to pay something like $400/year. And, they did this without any warning to their registered subscribers. Well, I've dumped Photobucket.

After doing some research, I've switched to vgy.me for photo hosting and updated this thread. If vgy.me pulls the same stunt at a later date, then I won't be updating again, as it takes too much precious time.
 

boertje

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May 24, 2002
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Coeur d'Alene, ID
TDI
'01, '01, '03 - TDIs all.
I had made pdfs on the howtos I've done so all is not lost should any other hosting service demand big money for their services.
 

UhOh

Top Post Dawg
Joined
Dec 24, 2014
Location
PNW
TDI
2000 & 2003 Golf GLS
Just a note to mention that there are cam indexing tools that don't require pulling the valve cover.
 

oldpoopie

Vendor
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May 14, 2001
Location
Portland Oregon
TDI
2001 golf gl, 2006 jetta, 1981 ALH swapped rabbit pickup, 1998 beetle
As some of you probably know, Photobucket made a decision to require those of us that use them for pictures on forums like TDI Club to pay something like $400/year. And, they did this without any warning to their registered subscribers. Well, I've dumped Photobucket.
After doing some research, I've switched to vgy.me for photo hosting and updated this thread. If vgy.me pulls the same stunt at a later date, then I won't be updating again, as it takes too much precious time.
Bummer. But you know tdiclub has its own photo hosting?
 

Tmorgan1988

Member
Joined
Aug 11, 2017
Location
Colorado
TDI
2001 Jetta tdi
Need help!

Hi there I bought a 2001 Jetta tdi auto, with help reading many articles on this club I completed the 5 speed swap, went very smooth! I then had some running issues read some more articles and found my in tank unit was clogged so I replaced it. My problem is my injection pump is getting seriously hot! While using vag com tdi timing my fuel temp goes from an average of 140 to 200 ! Any ideas, has my injection pump over worked itself by previous owner? Thanks
 

Nevada_TDI

Veteran Member
Joined
Aug 17, 2008
Location
Reno, sort of...
TDI
2001 Jetta TDI
Generally speaking, if the pump is getting hot it is because the thermo-tee on the top of the filter is not opening and allowing the fuel to circulate back to the tank to allow fresh fuel in to the filter and then into the pump head keeping it cool. I will suggest if the fuel pickup was plugged for any length of time damage could have been done to the pump internals; I only know this as I recently went through the same thing. As far as swapping out the injection pump w/o removing the timing belt goes we were in and out in less than 1 hour yesterday, it can be done but you have to know how to prevent the loss of proper timing. We used quite a few clamps, though. If your pump is junk, contact Dutch Auto Parts for the fastest and least expensive way to get a replacement. See post #1 :
http://forums.tdiclub.com/showthread.php?t=434593
 

4thbugTDI

New member
Joined
Jun 2, 2004
Location
Maryland
TDI
2004 Golf TDI
I need to remove my injector from my 2000 NB parts car(ie, head already removed). Is there a way I can get it off without buy the counterhold tool? I still want to sell the engine for parts and don't want to destroy anything.

Thanks,
Lance
 

eddie_1

Veteran Member
Joined
Dec 27, 2004
Location
Hannover, Germany formerly Toronto & NY
TDI
Jetta Wagon 2003 TDI tuned to 170HP, A6 Wagon 2008 TDI 2.7L tuned to 340HP
I need to remove my injector from my 2000 NB parts car(ie, head already removed). Is there a way I can get it off without buy the counterhold tool? I still want to sell the engine for parts and don't want to destroy anything.

Thanks,
Lance
To remove injectors I use a crow foot wrench.
 

arne487

Veteran Member
Joined
Jan 16, 2008
Location
Fort Collins, CO
TDI
'03 Golf TDI, '10 TDI Cup Jetta
If you're not putting a timing belt back on then just take the pump off and leave it. No need to worry about crank/cam position if you're scavenging parts. Just don't put the car in gear and roll it around if there's no timing belt on it.


Edit: I just reread you don't have a head on the engine. No risk of damage if there aren't any valves! Just take off whatever you want.

I need to remove my injector from my 2000 NB parts car(ie, head already removed). Is there a way I can get it off without buy the counterhold tool? I still want to sell the engine for parts and don't want to destroy anything.

Thanks,
Lance
 
Last edited:

Lock_t

Veteran Member
Joined
Apr 20, 2016
Location
Bucks Co. Pa
TDI
2001 Golf 5spd 221k
so swapping IPs doesn't need VC removal, do you HAVE to take cam sprocket off or even vacuum pump off? theoretically wouldn't you be able to loosen the tensioner, pull the belt, keep an eye on TDC mark on flywheel and just swap pumps being that you have the pump locked at TDC? or am i missing something crucial?
 

oldpoopie

Vendor
Joined
May 14, 2001
Location
Portland Oregon
TDI
2001 golf gl, 2006 jetta, 1981 ALH swapped rabbit pickup, 1998 beetle
Why don’t you try that out and let us know how it works out...
 

jokila

Vendor
Joined
Dec 3, 2004
Location
Houston, Texas
TDI
2003 Jetta GLS, Manual
so swapping IPs doesn't need VC removal, do you HAVE to take cam sprocket off or even vacuum pump off? theoretically wouldn't you be able to loosen the tensioner, pull the belt, keep an eye on TDC mark on flywheel and just swap pumps being that you have the pump locked at TDC? or am i missing something crucial?

Have you done a timing belt on an ALH?


Consult the timing belt procedure for further info. http://pics3.tdiclub.com/articles/pdf/a4timingbelt.pdf
 

Lock_t

Veteran Member
Joined
Apr 20, 2016
Location
Bucks Co. Pa
TDI
2001 Golf 5spd 221k
Not yet I've been reading into it though. I'm just talking about IP swap though, I mean I realize cam would need to be locked but otherwise I was more or less curious
 

Lock_t

Veteran Member
Joined
Apr 20, 2016
Location
Bucks Co. Pa
TDI
2001 Golf 5spd 221k
I mean I'll try anything once unless I find research proving it won't work. Don't think that everybody on here that asks questions doesn't do their research.
I have looked at it thanks appreciate all the wonderful insight
 

BobnOH

not-a-mechanic
Joined
May 29, 2004
Location
central Ohio
TDI
New Beetle 2003 manual
Yes, we do assume a lot, or we take nothing for granted.
so swapping IPs doesn't need VC removal, do you HAVE to take cam sprocket off or even vacuum pump off? theoretically wouldn't you be able to loosen the tensioner, pull the belt, keep an eye on TDC mark on flywheel and just swap pumps being that you have the pump locked at TDC? or am i missing something crucial?
Believe what he meant to say was no, that won't work.
 

Lock_t

Veteran Member
Joined
Apr 20, 2016
Location
Bucks Co. Pa
TDI
2001 Golf 5spd 221k
...i did a pump swap in his driveway 25 minutes start to finish including hammer modding the manual pump... totally uneccessary to remove the VC during a swap ... just establish tdc first and have the pump pin handy
so what's the scoop with this?
 

Lock_t

Veteran Member
Joined
Apr 20, 2016
Location
Bucks Co. Pa
TDI
2001 Golf 5spd 221k
As Jim states, if the engine was timed correctly and the pin goes in then it is close to TDC.
Verify with the flywheel timing mark, of course.
right so if you can see TDC mark on flywheel through trans hole and not messing with timing other than strickly working on IP wouldn't it be somewhat of an easy swap? or am i looking at this through too much of a tight lens?
 

jokila

Vendor
Joined
Dec 3, 2004
Location
Houston, Texas
TDI
2003 Jetta GLS, Manual
right so if you can see TDC mark on flywheel through trans hole and not messing with timing other than strickly working on IP wouldn't it be somewhat of an easy swap? or am i looking at this through too much of a tight lens?
That's the right thing to do but you still need to follow the part of the timing belt procedure on how to set the tensioner properly. That is why i posted the timing belt pdf for you.

You are going to need to pop the sprocket off the camshaft and then at some point torque the sprocket back on. You really want the camshaft index/lock tool to be there to ensure it stays in the correct position. The crank is easy to see whether it's in position or not.
 
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