Pump-Injector Unit, removing and installing
Recommended special tools and equipment
- VW 387 dial gauge holder
- 3410 socket insert
- T10054 hex ball socket
- T10055 extractor
- V.A.G 1331 torque wrench (5 to 50 Nm)
Without illustration:
- Dial gauge
Removing
- Remove upper toothed belt guard and cylinder head cover.
- Rotate crankshaft until cam pair of respective Pump-Injector Unit to be installed and removed face upward uniformly.
- Loosen lock nuts of adjustment screws -1- and remove adjustment screws.
- Loosen mounting bolts -2- for rocker arm axle from outside to inside using 3410 socket insert and remove rocker arm axle.
- 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.
Note the cylinder allocation of the Pump-Injector Units.
- Insert extractor (T10055) in place of tension block into lateral slot of Pump-Injector Unit.
- Using careful knocking motions, pull Pump-Injector Unit upward out of its cylinder head seat.
Installing
NOTE:
- For each step which requires an adjustment of Pump-Injector Unit, adjustment bolt in rocker arm and the ball pin for Pump-Injector Unit must be replaced.
- New Pump-Injector Units are shipped with O-rings and heat protection seal.
- If old Pump-Injector Unit is re-installed, the O-rings and heat protection seal must be replaced. Refer to O-rings for Pump-Injector Unit, removing and installing .
- Before installing Pump-Injector Unit, check that the three O-rings, heat protection seal and securing ring are seated properly.
NOTE:
O-rings must not be twisted on themselves.
- Oil O-rings and insert Pump-Injector Unit with great care into cylinder head seat.
- Drive Pump-Injector Unit in using uniform pressure into cylinder head seat until stop.
- Insert tension block into lateral slot of Pump-Injector Unit.
NOTE:
If Pump-Injector Unit does not stand at right angle to tension block, mounting bolt can loosen and thereby cause damage to Pump-Injector Unit / cylinder head.
Align Pump-Injector Unit as follows:
- Screw in the new mounting bolt as far into tension block so that the Pump-Injector Unit can still be turned lightly.
- Align Pump-Injector Unit at right angle to thrust bearing of camshaft.
- Using a caliper gauge (measuring range minimum 400 mm), check dimension "a" from outer edge of cylinder head to round surface of Pump-Injector Unit.
| 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 | |
- Re-align Pump-Injector Unit if necessary and tighten mounting bolt as follows:
- Tighten securing bolt to 12 Nm plus an additional 270 ° (3/4 turn) (additional rotation can occur in several stages).
- Install rocker arm axle and tighten new securing bolts as follows:
- First tighten inner bolts -2-, then outer bolts -1- uniformly hand-tight. Then in the same sequence, uniformly tighten to 20 Nm and turn 90° (1/4 turn).
- Set dial gauge onto adjustment bolt of Pump-Injector Unit as shown.
- Rotate crankshaft in direction of engine rotation until rocker arm roller stands at camshaft point.
Roller side (arrow -A-) stands at highest point
Dial gauge (arrow -B-) stands at lowest point
- Remove dial gauge.
- Turn adjustment bolt into rocker arm until significant resistance is noticeable (Pump-Injector element stands at stop).
- Turn back adjustment bolt from stop approx. 225 °.
- 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 toothed belt guard.