Pump Injector Unit
Pump Injector Unit
Special tools, testers and auxiliary items required
• Dial Gauge Holder (VW 387)
• Socket Insert (3410)
• Special Wrench, Long Reach (T10054)
• Puller (T10055)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Gauge (T10210)
• Dial Gauge
Removing
- Remove the acoustic cover and cylinder head cover of the applicable cylinder head.
- Rotate the crankshaft until the cam pair of the respective pump injector unit to be installed and removed face upward simultaneously.
- Loosen the lock nuts of the adjustment screws - 1 - and unscrew the adjustment screws far enough until the respective rocker arm makes contact at the plunger spring of the pump injector unit.
- 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 the bolt - 3 - for the tension block using the special wrench, long reach (T10054) and remove the tension block.
- Pry out connector from pump injector unit using a screwdriver. In order to avoid tilting, support the opposite side of the connector with light finger pressure.
- Set the puller (T10055) in place of the tension block into the side slit of the pump injector unit.
- Using careful knocking motions, pull the pump injector unit upward out of its cylinder head seat.
Installing
• Install a new pump injector unit, also replace the corresponding adjustment screw in the rocker arm.
• 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 are shipped with O-rings and heat protection seal.
- Install the pump injector unit again, replace the O-rings and the heat protection seal. Refer to => [ Pump Injector Unit O-ring ] Pump Injector Unit O-ring.
- Before installing the pump injector unit, check that the three seals, heat protection seal and securing ring are seated properly.
• Seals must not be twisted on themselves.
- Oil the seals and insert the pump injector unit with great care into cylinder head seat.
- Using uniform pressure, push the pump injector unit into the cylinder head seat onto the stop.
- Insert the tension block into the lateral slot of the pump injector unit.
• If the pump injector unit does not stand at a right angle to the tension block, the bolt can be loosened and thereby cause damage to the pump injector unit/cylinder head.
Align the 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.
- Insert the gauge (T10210) between the thrust bearing and pump injector unit as shown.
- Turn the pump injector unit against the gauge by hand.
- Align the pump injector unit, if necessary, and tighten the bolt as follows: 12 Nm + 270° (3/4) additional turn (tightening can be done in steps).
- Install the rocker lever shaft and tighten new bolts as follows.
- Tighten, first the inner and then both outer bolts by hand. Tighten to 20 Nm + 90° (1/4) additional turn in the same sequence.
- Place a dial gauge as shown onto the adjustment screw of the pump injector unit.
- Rotate the crankshaft in engine rotation direction until the rocker arm roller stands at the camshaft point.
• Roller side - arrow A - is positioned at the highest point
• Dial gauge - arrow B - is positioned at lowest point
- Remove the dial gauge.
- Now, thread the adjustment screw into the rocker arm against the spring force of the pump injector unit until significant resistance is detected (pump injector unit is positioned at the stop).
- Turn back the adjustment screw from the stop approximately 180°
- Hold the adjustment screw in this position and tighten the lock nut to 30 Nm.
- Connect the connector to the pump injector unit and install the cylinder head cover and acoustic cover.