Unit injector, removing and installing: Installing

WARNING: This page is about a different car, the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

If a new unit injector is installed, the appropriate adjustment screw in the rocker arm must also be replaced.
Each time work is performed which requires the unit injector to be adjusted, the adjustment screw in the rocker arm and also the unit injector ball pin must be cleaned and checked for signs of wear. If wear is evident the ball pin and the adjustment screw must be replaced.
New unit injectors are supplied with O-rings and heat shield seal.

Replace heat shield seal and O-rings if old unit injector is reused. Refer to O-rings for unit injector, removing and installing .
Check that three O-rings, heat shield seal and circlip are seating correctly before installing unit injector.

NOTE:

The seals must not be twisted.

Oil seals and install unit injector into cylinder head with great care.
Push unit injector evenly into cylinder head onto its limit stop.
Install tensioning block into slot on side of unit injector.

NOTE:

If the unit injector is not at right angles to the tensioning block the securing bolt may loosen and this can damage the unit injector or the cylinder head.

Align the unit injector as follows:

Screw new securing bolt into tensioning block until unit injector can still just be turned easily.
Align unit injector at right angles with camshaft bearing caps.

Fig 1: Identifying Dimension "a"

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Check dimension "a" from outer edge of cylinder head to rounded edge of unit injector with a vernier gauge (measuring range: min. 400 mm).

Cylinder		"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

If necessary realign unit injector.

Tighten securing bolts as follows:

Tighten bolts to 12 Nm and turn 270 ° 34 further (turning further can be done in several stages).

Fig 2: Identifying Mark On Rocker Arm Shafts

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Install rocker arm shaft and tighten new securing bolts as follows:
First tighten inner bolts - 2 - and then outer bolts - 1 - hand tight. Then, using same sequence, tighten to 20 Nm and turn 90 ° ( 14 ) further.

Fig 3: Identifying Special Tool VW 387

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Mount dial gauge onto adjustment screw of unit injector as shown.
Turn crankshaft in engine direction of rotation until roller of rocker arm is positioned on peak of drive cam lobe, roller side - arrow A - is positioned at highest point and dial gauge - arrow B - positioned at lowest point.
Remove dial gauge.
Turn adjustment screw inward into rocker arm until a firm resistance is felt (unit injector positioned at limit stop).

Fig 4: Adjusting Screw 225°

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Turn adjustment screw 225 ° back off limit stop.
Hold adjustment screw in this position and tighten lock nut to 30 Nm.
Connect unit injector connector and install cylinder head cover. Refer to Cylinder head cover, removing and installing and toothed belt guard, refer to Toothed belts, removing, installing and tensioning .