Does your Beetle have a check engine light? Does you Beetle make a loud screaching sound right after it'scold started? Does you Beetle have a "Secondary Air Insuficient Flow" code? Well,you might have an injection pump with broken rivets! The good news: it's very easy to fix and takes about an hour or less. The bad news is, it's expensive (about 2 bucks for screws and then 1000 dollars to me for writing this amazing writeup!
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Ok, start by removing the plastic shield on the top of the engine. There's screws holding it on (2 in the front under little covers, and one straight back from the oil fill cap). Onceyou get it off, look down the front of the engine, just under the intake manifold and you'll see the black plastic pump:
Next, remove the hose from the pump to the air box. Then disconnect the pump end of the other (smaller) hose. Next, remove the small bracket on the far right side of the intake manifold that has the plastic clamps for the 2 air injection hoses and the coolant hose below. Not too bad to get off.
The pump is mounted to a bracket which is held to the intake manifold by 3 bolts. They are allen heads. Remove them:
The pump's bracket must come off to get the pump out. So you'll have to rotate the pump around in the small space it's in to get to the 3 bolt holding the pump to the bracket. It's very tight but the pump will rotate with a little manipulation of the coolant and AC hoses.
Next, disconnect the electrical connection on the back of the pump. You'll need a flat head screw driver to GENTLY pry the small tab on the end under the connector comes loose. The remove the bracket and then manipulate the pump out of the engine bay. It's tight, but it'll come.
The rivets that hold the pump together are very cheap aluminum rivets. Apparently, they break.
Here's what the bottom of the pump looked like and why it threw a code:
And the broken rivets:
These are the screws you'll need (get 6 of them and make sure they come with nuts):
Next, take a drill and bit that's about the same size as the heads of the rivets and LIGHTLY drill them until the heads of the rivets break off:
Then, gently remove the outter layer of the pump (the cap with the air hose connection that came from the airbox) bringing the rivets out with it. Tap the rivets out of the pump, replace the cap onto the pump in the same position it was, and then install the screws:
Finally, reinstall the pump in the reverse order you removed it. Here's the pump installed with the new screws:
THAT'S IT!
