Withdrawal
Remove cylinder head cover. Rotate the crankshaft until the pair of lobes of each unit injector to be installed or removed are pointing evenly upwards.
Loosen the locknuts of the adjusting bolts -1- and unscrew the adjusting bolts so that the corresponding rocker arm rests on the spring of the pusher of the unit injector. Unscrew bolts -2- for rocker shaft from outside to inside using tool 3410 and remove rocker shaft. Loosen bolt -3- of clamping jaw using tool -T10054- and remove clamping jaw.
Unplug the unit injector with a screwdriver -arrow-. To avoid distortion, support the opposite side of the plug connector while applying light pressure with your finger.
Attach puller -T10055- instead of block in side slot of unit injector. Remove the unit injector with gentle tapping movements upwards from the corresponding socket in the cylinder head.
Installation
Instruction. During any work related to the adjustment of the unit injector, it is necessary to replace the adjusting bolt in the rocker arm and the bolt with the ball head of the unit injector. New unit injectors are supplied with O-rings and a heat seal. When installing a new unit injector, the corresponding adjusting bolt in the rocker must also be replaced. When reinstalling a used unit injector, the seal must be replaced. rings and heat seal.
Before installing the unit injector, check the correct fit of the three seals. rings, heat seal and retaining ring. Twisting of seals is not allowed. rings. Lubricate seal. rings and very carefully install the unit injector into the cylinder head socket. Pressing evenly, insert the unit injector into the socket on the cylinder head as far as it will go. Install the clamping block in the side slot of the unit injector.
Instruction. If the unit injector is not at right angles to the clamping shoe, the fixing bolt may come loose, resulting in damage to the unit injector or cylinder head.
Align the unit injector as follows: Screw new mounting bolts into the clamping block so that the unit injector can be easily rotated. Now align the unit injector at right angles to the camshaft support brackets.
Check with caliper -VAS 5276- (measuring range min. 400 mm) distance "A" from the outer edge of the cylinder head to the round surface of the unit injector.
Pump injectors with a cylindrical shoulder to the nut
Cylinder | Size "A" |
1 | 244.2±0.8mm |
2 | 152.8±0.8mm |
3 | 64.8±0.8mm |
Pump injectors with beveled collar to nut
Cylinder | Size "A" |
1 | 245.0±0.8mm |
2 | 157.0±0.8mm |
3 | 65.6±0.8mm |
All cars
If necessary, align the unit injector again and tighten the fixing screws of the clamping jaw: tightening torque: 12 Nm + tighten by 270°. Install the rocker shaft and tighten the new fixing bolts as follows: tighten the inner bolts first and then the outer bolts in several steps. Tightening torque in the same sequence: 20 Nm + tighten by 90°. Install a dial indicator on the adjusting bolt of the unit injector as shown in the figure.
Rotate the crankshaft in the direction of engine rotation until the rocker roller is at the end of the drive cam. The roller side -arrow A- is at its highest point, the dial indicator -arrow B- is at its lowest point. Remove the dial indicator. Now screw the adjusting bolt into the rocker so that you feel a noticeable resistance (pump injector screwed up to the stop).
Turn the adjusting bolt with the special tool (torque wrench -VAG 17'5.6-) back from the stop by 180°. While holding the adjusting bolt in this position, tighten the locknut (tightening torque: 30 Nm). Connect the plug connector of the unit injector. Install the cylinder head cover and toothed belt cover.
Visitor comments