Pump Injector Unit

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

Special tools and workshop equipment required

Dial gauge holder VW 387
Multi point socket 3410
Multi point socket T10054
Removal tool T10055
Torque wrench V.A.G 1331

Removing

-- Remove the upper toothed belt guard.

-- Remove cylinder head cover, refer to CYLINDER HEAD COVER .

-- Rotate crankshaft until cam pair of respective pump injector unit to be installed and removed face upward simultaneously.

-- Loosen the lock nut of the adjustment screw -1- and remove the adjustment screw.

Fig 1: Identifying Lock Nuts And Securing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 mounting 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.

Observe the cylinder allocation of the pump-injector units.

-- Set the removal tool T10055 in place of the tension block into the side slit of the pump injector unit.

Fig 2: Identifying Seat Puller T10055

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the pump injector unit upward and out of its seat in the 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.

-- Install the pump injector unit again, replace the O-rings and the heat protection seal, refer to PUMP INJECTOR UNIT O-RING .

-- Before installing pump injector unit, check that the three sealing rings, heat protection seal and securing ring are seated properly.

NOTE:

Sealing rings must not be twisted on themselves.

-- Oil the seals and insert the pump injector unit with great care into the seat in the cylinder head.

-- Using uniform pressure, push the pump injector unit into the cylinder head seat onto the 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 the new bolt into the tension block so far that the pump-injector unit can still be lightly turned.

-- Now align pump injector unit at right angle to thrust bearing of camshaft.

-- Using a caliper gauge (measuring range at least 400 mm), check dimension -a- from the outer edge of the cylinder head to the round surface of the pump injector unit.

Fig 3: Identifying Dimension "a"

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Realign pump injector unit if necessary and tighten securing bolt as follows: 12 Nm and 270° (³ /₄ turn) further. Additional turn can occur in several stages.

-- Install rocker arm axle and tighten new securing bolts as follows:

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

Fig 4: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place a dial gauge as shown onto the adjustment screw of the pump injector unit.

Fig 5: Identifying Dial Gauge Set Onto Adjustment Bolt Of Pump-Injector Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Rotate crankshaft in direction of engine rotation until rocker arm roller stands at camshaft point. Roller side -arrow A- is positioned at the highest point, dial gauge -arrow B- is positioned at the lowest point.

-- Remove the dial gauge.

-- Now turn adjustment bolt into rocker arm until significant resistance is noticeable (pump injector unit positioned on stop).

-- Turn back adjustment bolt from stop approximately 180 degrees

Fig 6: Identifying Adjustment Bolt Turned Back 180 Degrees To Tighten Lock Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Hold adjustment bolt in this position and tighten lock nut to 30 Nm.

-- Connect the connector to the pump injector unit.

-- Install cylinder head cover, refer to CYLINDER HEAD COVER .

-- Install toothed belt guard.