How involved is replacing an injection pump?

[heyisforhumans]

I just got this 86 N/A golf http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=170381449902&viewitem=&_trkparms=tab%3DWatching#ht_536wt_958 and it's so nice and so clean and anyway I'm thinking of the Giles injection pump upgrade and so I was wondering how much is involved in making the exchange?  I just ordered a Bentley manual but it probably won't be here for another week. Okay anyway I look forward to hanging out with you all on the forum now... I've been looking around for a few days and this place looks great. Thanks! -James

[jack's lack]

It will all be in the Bentley, and it is not too difficult. You will need to retime the pump however and that is the trickiest part, but if you follow procedure it should be no problem. you will need a few specialty tools, a camlock plate, a pin to lock the pump cog, an spanner wrench for the tensioner, and a dial indicator with adaptor for the pump itself. Giles will probably tell you to set your timing to .95mm. This is the perfect time to change your timing belt, and since these are interference engines it would be foolish not to. I would change the belt tensioner and the seal on the waterpump at this time as well since they are cheap and will be accessible and are otherwise a total PITA to get to. Good luck with your new purchase

[heyisforhumans]

how do you like your giles pump?

[ilikevwdiesel]

steam clean the engine. remove the air filter cover and crankcase vent hose on valve cover. remove the valve cover and timing cover (upper half). bring the engine to #1 cyl. TDC. Insert the special lock plate in the transmission end of the cam and the special lock pin in the injection pump sprocket. Loosen the cam sprocket bolt and injection pump sprocket nut. Loosen the timing belt tensioner nut. Remove the cam sprocket bolt. Using a plastic dead blow hammer break the cam sprocket free from the cam (place a CLEAN block of wood against the camshaft side of the sprocket and strike that if you only have a steel hammer to avoid marring the sprocket teeth) and set it aside. The timing belt will now be slack. Remove the injection pump pulley nut. Using a puller (special ones are available but universal ones will work), remove the injection pump sprocket, and the keyway from the injection pump shaft. Set aside.  remove the steel injection pump fuel lines from the injection pump/injectors. Cap the injectors to keep dirt out. Remove the 4 injection pump mounting bolts. Lift the pump off the mounting bracket, set it on the radiator/core support and remove the cold start cable from the back side of the pump. that's how you REMOVE the injection pump. Putting it back on is a whole nutha story...

[Vincent Waldon]

Timing it kinda looks like this;

http://vincewaldon.com/index.php?option=com_content&task=view&id=24&Itemid=28

[heyisforhumans]

looks great, thanks!