Removal and installation of the pump-injector (VW Passat B6)

Removal

Remove the upper part of the timing belt cover and the cylinder head cover.

Loosen the locknuts of the adjusting screws and unscrew the adjusting screws until the corresponding rocker rests on the spring of the pump-injector pusher.



Loosen the 5-1 roller lever axle mounting bolts from outer to inner using a socket and remove the roller lever axle (fig. 2.316).



Remove the cable connection of the pump injectors and glow plugs.

Loosen the mounting bolts of the unit injectors using a nozzle and remove the bolts.

Remove the ball head bolt from the unit injector.



Install the puller into the bolt holes of the unit injector (fig. 2.364).

Gently rotate axis A away from the pump-injector. Tighten lock nut B by hand.

Using a hammer, tap the unit injector upwards from its seat on the cylinder head.

Note: Do not interchange previously used unit injectors.

Installation

The pump injector mounting screws must be replaced in any case.

Attention: When performing any work related to adjusting the pump-injector using the adjusting screw, it is necessary to replace the adjusting screw in the rocker arm and the screw with the ball head of the pump-injector, otherwise increased wear of these parts will occur.

Before installing the pump-injector, check that the new sealing rings are seated correctly.

Note: New unit injectors are supplied complete with O-rings.

Note: When installing an old unit injector, the sealing rings must be replaced.

Note: The sealing rings must not be twisted.

Note: Lubricate the O-rings and the stem of the unit injector with oil.

Note: Check the seat under the pump-injector in the cylinder head for contamination (for example, shavings, soot, etc.), clean with compressed air if necessary.

Very carefully insert the pump injector into the seat on the cylinder head.



Install the mounting device with 2036/1, as shown in Figure 2.365, on the cylinder head support frame.

Caution: If the unit injector is overtightened with the mounting screws, there is a risk of it becoming skewed. This may result in poor driving performance and problems with starting the engine. Therefore, the unit injector should first be pressed into the seat and only then screwed on.

Insert new mounting screws and tighten them by hand without applying force until they stop (fig. 2.366).

Insert the valve puller with the mandrel.



Press the pump-injector into its seat using a valve puller and hold it in this position (fig. 2.367).

Tighten the pump injector mounting screws by hand without applying force, using an insert until they stop.

Tighten the new mounting screws as follows:

• stage 1 - 3 Nm;
• stage II - 90° (1/4 turn);
• stage III - 180° (1/2 turn).

Note: Replace the adjusting screws A and the ball head bolt of the unit injector.

Install the roller lever axle and tighten the new fasteners evenly in sequence 1–5 by hand (fig. 2.316).

Then tighten evenly in the same sequence with 20 Nm + turn by 90° (1/4 turn).

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Install the micrometer as shown in Figure 2.368 on the adjusting screw of the unit injector.

Rotate the crankshaft in the direction of engine rotation until the rocker roller is at its highest point. Roller side A is at its highest point. Indicator B is at its lowest point

Remove the micrometer.

Then screw the adjusting screw into the rocker arm until you feel a noticeable resistance (the pump-injector is screwed in all the way).



Turn the adjusting screw from the "tightened to the stop" position by 180° (fig. 2.369).

Hold the adjusting screw in this position and tighten the lock nut to 30 Nm.

Install the pump-injector plug and install the cylinder head cover and timing belt cover.