Fuel Injector: Testing and Inspection

Pump Injector Unit Pump Piston Position, Checking and Adjusting

Special tools, testers and auxiliary items required

• Clamping Device (T10199)

• Socket XZN 16 (T10198)

• Camshaft Tool (T10195)

• Drive Insert (T10336)

• Dial Gauge Set, 4 Part (VAS 6341)

• Dial Gauge Holder (VW 387)

Requirement:

• Engine is removed

Procedure:

• The measurement or adjustment with cylinder bank 1 must be done on cylinder 1. With cylinder bank 2, the engine must be rotated 360° out of Top Dead Center (TDC) and the measurement or adjustment must be done on cylinder 7.

- Remove the acoustic cover and cylinder head cover of the applicable cylinder head.

- Remove the fuel or tandem pump from the respective cylinder head. Refer to => [ Tandem and Fuel Pump ] Tandem and Fuel Pump.

- Rotate the engine using the counterhold tool Touareg V10 (T10172) to TDC, refer to => [ Valve Timing, Checking ] Adjustments and remove the vibration damper. Refer to => [ Front Sealing Flange and Vibration Damper Overview ] Description and Operation.

- Install the camshaft tool (T10195).

- Position the dial gauge from the dial gauge set, 4 part (VAS 6341) using the dial gauge holder (VW 387) and approximately 1 mm pretension as shown on the pump injector unit spring seat.






- Remove the camshaft tool (T10195) pin and rotate the engine opposite engine rotation direction until the dial gauge needle no longer moves.

- Set the dial gauge to "0".






- Now, turn the engine again in engine rotation direction to TDC and insert the camshaft tool securing pin.

- Read out the value on dial gauge.

Specified Values

• Engine code BKW: 5.18 mm +/- 0.1 mm

• Engine code BWF: 4.95 mm +/- 0.1 mm

If the specified value is achieved:

- Reassemble the engine.

If the specification is not obtained:

- Install the clamping device (T10199) on the camshaft gear and tighten the bolts to 40 Nm.

- Loosen the camshaft gear bolt - B - using the socket XZN 16 (T10198).






- Rotate the camshaft using the drive insert (T10336) until the specified value is reached.

- Tighten the camshaft gear bolt to the 2nd pass, refer to => [ Tightening Specifications ] Service and Repair and then measure again.

- If the specified value is reached, then tighten the bolt for the camshaft gear to the 3 pass, refer to => [ Tightening Specifications ] Service and Repair.

- Reinstall the cylinder head cover, refer to => [ Cylinder Head Cover Bolt Tightening Sequence ] Cylinder Head Overview as well as the acoustic cover.