Pump Injector Unit
Pump Injector Unit
Special tools, testers and auxiliary items required
• Dial gauge holder (VW 387)
• Multi-point socket (3410)
• Multi-point socket (T10054)
• Puller (T10055)
• Torque wrench (V.A.G 1331)
• Dial gauge
• Grease (G 000 100)
• With the introduction of the extended service interval for LongLife Service, the setting screw - 1 - and the ball pin - 2 - for the pump injector unit have been changed. On older engines without the extended service interval, a mixed installation is permissible.
Removing
- Remove the upper toothed belt shield and the cylinder head cover => [ Cylinder Head Cover ] .
- Rotate crankshaft until cam pair of respective pump-injector unit to be installed and removed face upward simultaneously.
- Loosen the lock nut of the adjustment screw - 1 - and remove the adjustment screw.
- Loosen the bolts - 2 - for the rocker lever shaft from the outside toward the inside, using the socket insert (3410) and remove the rocker lever shaft.
- Loosen mounting bolt - 3 - for tension block using socket insert (T10054) and remove tension block.
- Pry out connector from pump-injector unit using a screwdriver. In order to avoid canting, support opposite side of connector with light finger pressure.
Observe the cylinder allocation of the pump-injector units.
- Set the puller (T10055) in place of the tension block into the side slit of the pump-injector unit.
- Using careful knocking motions, pull pump-injector unit upward out of its cylinder head seat.
Installing
• Install a new pump-injector unit, also replace the corresponding adjustment bolt in rocker arm.
• For every procedure that requires adjustment of the pump-injector unit, the adjustment screw in the rocker lever and also the ball pin of the pump-injector unit must be replaced.
• On the older versions of the pump injector unit, grease the contact surfaces between the ball pin and the adjustment bolt with (G 000 100).
• New pump-injector units come equipped with O-rings and heat protection seal.
- Install the pump-injector unit again, replace the O-rings and the heat protection seal => [ Pump Injector Unit O-rings ] Pump Injector Unit O-rings.
- Before installing pump-injector unit, check that the three O-rings, heat protection seal and securing ring are seated properly.
• O-rings must not be twisted on themselves.
- Oil O-rings and insert pump-injector unit with great care into cylinder head seat.
- Using uniform pressure, push the pump-injector unit into the cylinder head seat onto the stop.
- Insert tension block into lateral slot of pump-injector unit.
• If pump-injector unit does not stand at right angle to tension block, securing bolt can loosen and thereby cause damage to pump-injector unit/cylinder head.
- Align pump-injector unit as follows.
- Screw the new bolt into the tension block so far that the pump-injector unit can still be lightly turned.
- Now align pump-injector unit at right angle to thrust bearing of camshaft.
- Using a caliper gauge (measuring range at least 400 mm), check dimension " a" (see following illustrations) from the outer edge of the cylinder head to the round surface of the pump-injector unit.
• Introduction of pump injector units with new solenoid valve nut. A mixed installation is permissible under dimension "a".
Pump Injector Unit with The Old Solenoid Valve Nut
Pump Injector Unit with The New Solenoid Valve Nut
- Re-align pump-injector unit if necessary and tighten securing bolt as follows:
Tighten the securing bolts to 12 Nm and turn an additional 270° (3/4 rotation, additional rotation may occur in several stages).
- Install rocker arm axle and tighten new securing bolts as follows:
First, fasten the inner bolts - 2 -, then the outer bolts - 1 - hand-tight. Then, tighten in the same order to 20 Nm and turn 90° (1/4 turn).
- Place a dial gauge as shown onto the adjustment screw of the pump-injector unit.
- Rotate crankshaft in direction of engine rotation until rocker arm roller stands at camshaft point.
Roller side - arrow A - is positioned at the highest point, dial gauge - arrow B - is positioned at the lowest point.
- Remove the dial gauge.
- Now turn adjustment bolt into rocker arm until significant resistance is noticeable (pump-injector element stands at stop).
- Turn back adjustment bolt from stop approximately 225 degrees
- Hold adjustment bolt in this position and tighten lock nut to 30 Nm.
- Connect connector to pump-injector unit and install cylinder head cover and upper toothed belt guard=> [ Cylinder Head Cover ] .