Removal and installation of the pump-injector (diesel engine) (VW Touareg 1)

Removal

Remove the soundproofing cover and the cylinder head cover of the corresponding cylinder head.

Rotate the crankshaft until the pair of cams of the correspondingly installed or removed pump-injectors point evenly upward.

Loosen the locknuts of the adjusting screws 1 and unscrew the adjusting screws until the corresponding rocker rests on the spring of the pump-injector pusher.

Loosen the 2 outer to inner roller lever axle mounting bolts using socket wrench 3410 and remove the valve drive roller lever (fig. 2.291).



Unscrew the mounting bolt 3 of the spacer using the T10054 socket wrench and remove the spacer.



Disconnect the pump-injector plug with a screwdriver. Lightly hold the back of the plug with your finger to avoid distortion.

Install the T10055 puller in place of the spacer in the side groove of the pump-injector (fig. 2.292).



Using gentle tapping, remove the unit injector upwards from its seat on the cylinder head.

Installation

NOTE: When installing a new unit injector, the corresponding rocker arm adjusting screw must be replaced.

When performing any work related to adjusting the pump-injector, it is necessary to replace the adjusting screw in the rocker arm and the ball-head screw of the pump-injector.

New unit injectors are supplied complete with sealing rings and heat-protective seals.

The original text is available on the website VWmanual.ru

When installing an old unit injector, it is necessary to replace the O-rings and the heat-insulating seal.

Before installing the unit injector, check that the three sealing rings, the heat-insulating seal and the retaining ring are seated correctly.

NOTE: The O-rings must not be twisted.

Lubricate the sealing rings and very carefully install the unit injector into the socket on the cylinder head.


Pressing evenly, insert the pump injector into the socket on the cylinder head until it stops.

Install the spacer into the side groove of the pump injector.

NOTE: If the unit injector is not positioned at a right angle to the spacer, the mounting bolt may come loose, causing damage to the unit injector or cylinder head.

Install the pump injector as follows.

Screw the mounting bolts into the spacer until the pump injector can be easily rotated.

Install the T10210 template between the main bearing bed and the pump-injector (fig. 2.293).



Rotate the pump nozzle by hand in the direction away from the template.

Additionally, if necessary, center the unit injector and tighten the mounting bolt as follows: 12 Nm + 3/4 turn (270°) (additional tightening can be performed in several stages).

Install the new roller arm shaft and tighten the new mounting bolts as follows.

First the inner ones, then both outer ones by hand. Then in the same sequence with a torque of 20 Nm + 1/4 rev. (90°).

Install the micrometer on the adjusting screw of the pump-injector as shown in Figure 2.294.



Rotate the crankshaft in the direction of engine shaft rotation until the rocker arm roller is at its highest point.

The side of the roller, arrow A, is at its highest point.

Micrometer, arrow B, is at its lowest point.

Remove the micrometer.

Now turn the adjusting screw, compressing the spring of the pump-injector, 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. 2.295).



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 soundproof cover.