Fuel pump insulator block

[john east]

There's a youtube video which shows someone sanding down the sides of the plastic push rod guide so that it seats down under its own weight rather than having to be forced down to seat correctly. Apparently, if you don't do this simple operation there is a chance that it will stick in the block and possibly snap off near the bottom next time you try an lift it out. I did this to mine yesterday when fitting a new push rod. All working OK now.

[CovKid]

Yep. This mod dates back to the Beetle. The block gets extraordinarily hot and can make it more prone to snap, particularly if wedged in tight. I remember doing that before the T3 even existed.

[john east]

My main concern after a year of running problems, having only just sussed out and fixed the main cause, push rod was worn down 3mm, is how fuel pressure varies over time. Fortunately my annual mileage now is low, but I'd be worried after a couple of years if I was doing 20k annual mileage.