Pump-Injector Unit, Removing and Installing
Pump/injector Unit, Removing And Installing
Special tools, testers and auxiliary items required
- Universal dial gauge bracket VW387
- Socket 3410
- Socket T10054
- Puller T10055
- Torque wrench V.A.G1331
- Dial gauge
- Grease G 000 100
NOTE: With the introduction of the extended service intervals (long-life service) the adjustment screw - 1 - and the ball pin - 2 - of the pump/injector unit has been changed. In older engines without extended service intervals a mixed construction is permitted.
Removing
- Remove toothed belt guard upper part and cylinder head cover.
- Turn crankshaft until cam lobes of pump/injector unit to be installed/removed points evenly upward.
- Loosen adjustment screw lock nuts - 1 - and unscrew adjustment screws.
- Loosen securing bolts - 2 - for rocker shaft (starting on outside and working inward) with socket 3410 and take rocker shaft off.
- Loosen securing bolt - 3 - for tension block with socket T10054 and remove tension block.
- Remove connector from pump/injector unit. Carefully slide a small screwdriver down center of housing until securing tab is released and connector can be pulled free. To avoid canting, support opposite side of connector with light finger pressure.
NOTE: Do not interchange pump/injector units between cylinders.
- Insert puller T10055 instead of tension block into slot of pump/injector unit.
- Pull pump/injector unit off by knocking it out of cylinder head seat.
Installing
NOTE:
- If a new pump/injector unit is installed, the respective adjustment screw in the rocker lever must also be replaced.
- For work which requires an adjustment of the injector unit, the rocker lever adjustment screw and the pump/injector unit ball pin must replaced.
- Grease older pump/injector unit drive version contact surfaces between ball pin and adjustment screw with G 000 100.
- New pump/injector units are supplied with O-rings and a heat protection gasket.
- If the old pump/injector unit is installed, the O-rings and the heat protection gasket must be replaced.
- Check correct seat of three O-rings, heat protection gasket and safety ring before installing pump/injector unit.
NOTE: The O-rings must not be twisted.
- Oil O-rings and insert pump/injector unit with greatest care into cylinder head seat.
- Push pump/injector unit evenly into cylinder head onto its stop.
- Insert tension block into slot of pump/injector unit.
NOTE: If the pump/injector unit is not positioned at right angles to the tension block the securing bolt could loosen and cause damage to the pump/injector unit or the cylinder head.
- Align pump/injector unit as follows:
- Screw new securing bolt into tensioning block until pump/injector unit can still be turned easily.
- Align pump/injector unit at right angles with camshaft bearing caps.
- Check dimension "a" with a vernier gauge (measuring range 400 mm minimum - see following figures) from cylinder head outer edge to round surface of pump/injector unit.
NOTE: Pump/injector units with a new solenoid valve nut have been gradually introduced into production. A mixed construction is permitted when the dimension "a" is considered.
Pump/injector unit with old solenoid valve nut
Cylinder Dimension - a -
1 332.2 ± 0.8 mm
2 244.2 ± 0.8 mm
3 152.8 ± 0.8 mm
4 64.8 ± 0.8 mm
Pump/injector unit with new solenoid valve nut
Cylinder Dimension - a -
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
- Align pump/injector unit again, if necessary, and tighten securing bolt as follows:
- Tighten securing bolt to 12 Nm plus 3/4 turn (270 degrees). Extra 3/4 turn can be done in several stages.
- Position rocker shaft and tighten new securing bolts as follows:
- Tighten inner bolts - 2 - first and then outer bolts - 1 - hand-tight. Then tighten to 20 Nm plus 1/4 turn (90 degrees) in same sequence.
- Fit a dial gauge on pump/injector unit adjustment screw as shown in illustration.
- Turn crankshaft in engine direction of rotation until rocker lever roller is positioned on actuating cam point.
- Roller side - arrowA - is at highest point, dial gauge - arrowB - is at lowest point.
- Remove dial gauge.
- Install adjustment screw into rocker lever until a considerable resistance can be felt (injector element is onto limit stop).
- Turn adjustment screw 225 degrees back off stop.
- Hold adjustment screw in this position and tighten lock nut to 30 Nm.
- Connect pump/injector unit connector and install cylinder head cover and toothed belt guard upper part.