Replacement
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 (5 to 50 Nm) (VAG 1331)
• Gauge (T10210)
• Dial gauge
Removing
- Remove acoustic cover and cylinder head cover of the applicable cylinder head.
- Rotate crankshaft until cam pair of respective pump injector unit to be installed and removed face upward simultaneously.
- Loosen lock nuts of adjustment screws - 1 - and remove adjustment screws until respective rocker arm makes contact at plunger spring of pump injector unit.
- 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 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 tilting, support opposite side of connector with light finger pressure.
- 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 the ball pin of the pump injector unit must be replaced.
• New pump injector units are shipped with O-rings and heat protection seal.
- Install the pump injector unit again, replace the O-rings and the heat protection seal. Refer to --> [ Pump injector Unit O-rings ] Pump injector Unit O-rings.
- Before installing pump injector unit, check that the three sealing rings, heat protection seal and securing ring are seated properly.
• Sealing rings must not be twisted on themselves.
- Oil sealing 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 the pump injector unit as follows:
- Install the new bolt into the tension block so far that the pump injector unit can still be lightly turned.
- Insert gauge (T10210) between thrust bearing and pump injector unit as shown.
- Turn pump injector unit against gauge by hand.
- Realign pump injector unit if necessary and tighten bolt as follows: 12 Nm + 3/4 turn (270°) further (additional rotation can occur in several stages).
- Install rocker arm axle and tighten new bolts as follows.
- Tighten first the inner and then both outer bolts by hand. Then, in the same sequence to 20 Nm + 1/4 turn (90°) further.
- 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 highest point
• Dial gauge - arrow B - is positioned at lowest point
- Remove the dial gauge.
- Now thread adjusting screw into rocker arm against spring force of pump-injector unit until significant resistance is detected (pump-injector unit is positioned at stop).
- Turn back adjustment bolt from stop approximately 180°.
- Hold adjustment bolt in this position and tighten lock nut to 30 Nm.
- Connect the connector of the pump injector unit and install cylinder head cover and acoustic cover.