Pump-Injector Unit, removing and installing: Installing

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NOTE:

Install a new Pump-Injector Unit, also replace the corresponding adjustment bolt in rocker arm.
For each step which requires an adjustment of Pump-Injector Unit, adjustment bolt in rocker arm and also the ball pin for Pump-Injector Unit must be cleaned and examined for traces of wear. If there is wear, ball pin and adjustment bolt must be replaced.
Grease contact surface between ball pin and adjustment bolt with G 000 100.
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.
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, securing bolt can loosen and thereby cause damage to Pump-Injector Unit / cylinder head.

Align Pump-Injector Unit as follows.
Screw in the new securing bolt as far into tension block so that the Pump-Injector Unit can still be turned lightly.
Now align Pump-Injector Unit at right angle to thrust bearing of camshaft.

Fig 1: Identifying Dimension "a"

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 securing bolt as follows:
Tighten securing bolt to 12 Nm and

270 ° (3/4 turn) (additional rotation can occur in several stages).

Fig 2: Identifying Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install rocker arm axle and tighten new securing bolts as follows:
Tighten inner bolts -2- hand-tight, then outer bolts -1-. Then in the same sequence,

Tighten to 20 Nm plus an additional 90 ° (1/4 turn).

Fig 3: Identifying Special Tool VW 387

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set a 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 top.

Roller side (arrow -A-) stands at highest point

Dial gauge (arrow -B-) stands at lowest point

Remove dial gauge.
Now turn adjustment bolt into rocker arm until significant resistance is noticeable (Pump-Injector element stands at stop).

Fig 4: Adjusting Screw 225 Degrees

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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.