Pump-Injector Unit, Removing and Installing - I

Pump-Injector Unit, Removing And Installing







Special tools, testers and auxiliary items required
- Dial gauge holder VW 387
- Hex ball socket 3410
- - Hex ball socket T10054
- Removal tool T10055
- Torque wrench (5 to 50 Nm) V.A.G 1331

Removing
- Remove upper toothed belt guard.
- Remove cylinder head cover.
- Turn crankshaft until cam lobe pair for respective Pump-Injector unit point upward equally.







- Loosen lock nut of adjustment screw - 1 - and remove adjustment screw.
- Loosen bolts - 2 - for rocker lever shaft from outside toward inside, using socket insert 3410 and remove rocker lever shaft.
- Loosen bolt - 3 - for tension block, using socket insert T10054 and remove tension block.
- Remove connector from Pump-Injector unit. Carefully slide a small screwdriver down center of housing until securing tab is released and connector can be pulled free. To avoid canting, support opposite side of connector with light finger pressure.

NOTE: Observe the cylinder allocation of the Pump-Injector units.







- Set removal tool T10055 in place of tension block into side slit of Pump-Injector unit.
- Pull Pump-Injector unit upward and out of its seat in cylinder head through careful tapping movements.

Installing

NOTE:
- 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 come equipped with O-rings and heat protection seal.

- Replace Pump-Injector O-rings and heat protection seal.
- Before installing Pump-Injector unit, verify that sealing rings, heat protection seal and securing ring are correctly installed in their seats.

NOTE: The seals must not be twisted.

- Lubricate seals and insert Pump-Injector unit with extreme caution into its seat in cylinder head.
- By applying uniform pressure, push Pump-Injector unit into cylinder head seat up to limit stop.
- Set tension block into side slit of Pump-Injector unit.

NOTE: If the Pump-Injector unit is not positioned at a right angle to the tension block, the bolt can loosen and thereby result in damages to the Pump-Injector unit and cylinder head.

Align the pump-injector unit as follows:
- Screw new bolt into tension block just far enough so that Pump-Injector unit can still be slightly turned.
- Now, align Pump-Injector unit at a right angle to bearing blocks of camshaft.







- Using a caliper gauge (measuring range at least 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

- Align Pump-Injector unit, if necessary, and fasten bolt as follows: 12 Nm plus 270 degrees (3/4 turn). (Turning further may be performed in several steps.)
- Set rocker lever shaft in place and fasten new bolts as follows:







- First, fasten inner bolts - 2 -, then outer bolts - 1 - uniformly hand-tight. Then, tighten in same order to 20 Nm plus 90 degrees (1/4 turn) uniformly.







- Place a dial gauge as shown onto adjustment screw of Pump-Injector unit.
- Turn crankshaft in engine running direction until roller of rocker lever is positioned on tip of cam lobe. Roller side - arrow A - is positioned at highest point, dial gauge - arrow B - is positioned at lowest point.
- Remove dial gauge.
- Turn adjustment screw in rocker lever until considerable resistance is felt (Pump- Injector unit is on limit stop).







- Turn adjustment screw 225 degrees back from limit stop.
- Hold adjustment screw in this position and fasten lock nut to 30 Nm.
- Connect connector to Pump-Injector unit.
- Install cylinder head cover.
- Install toothed belt guard.