Pump-Injector Unit, Removing and Installing
Pump-Injector Unit, Removing And Installing
Only vehicles with engine code BEW
Recommended special tools and equipment
- VW 387 dial gauge holder
- 3410 Puller
- T10054 hex ball socket T10055 extractor
- V.A.G1331 torque wrench (5 to 50 Nm)
- Dial gauge
- G 000 100 grease
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 simultaneously.
- Loosen lock nuts of adjustment bolts -1- and unscrew adjustment bolts as far until respective rocker arm makes contact at plunger spring of Pump-Injector Unit.
- Loosen securing bolts -2- for rocker arm axle from outside to inside using 3410 socket insert and remove rocker arm axle.
- Loosen securing 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.
- Insert extractor 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:
- 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.
- 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.
- Re-align Pump-Injector Unit if necessary and tighten securing bolt as follows:
- Tighten securing bolt to 12 Nm and 270 degree (3/4 turn) (additional rotation can occur in several stages).
- 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 degree (1/4 turn).
- 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).
- Turn back adjustment bolt from stop approx.
225 degree.
- 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.