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)
• Removal tool (T10055)
• Torque wrench (V.A.G 1331)
Removing
- Remove the upper toothed belt guard.
- Remove cylinder head cover => [ Cylinder Head Cover ] Service and Repair.
- 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 removal tool (T10055) in place of the tension block into the side slit of the pump injector unit.
- Pull the pump injector unit upward and out of its seat in the cylinder head through careful tapping movements.
Installing
• 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 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-Ring ] Pump Injector Unit O-Ring.
- 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 the seals and insert the pump injector unit with great care into the seat in the cylinder head.
- 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 - from the outer edge of the cylinder head to the round surface of the pump injector unit.
- Realign pump injector unit if necessary and tighten securing bolt as follows: 12 Nm and 270° (3/4 turn) further. Additional turn can 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 - uniformly hand tight. Then, tighten in the same order to 20 Nm and turn 90° (1/4 turn) uniformly.
- 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 unit positioned on stop).
- Turn back adjustment bolt from stop approximately 180 degrees
- Hold adjustment bolt in this position and tighten lock nut to 30 Nm.
- Connect the connector to the pump injector unit.
- Install cylinder head cover => [ Cylinder Head Cover ] Service and Repair.
- Install toothed belt guard.