Volkswagen > Passat > 1998-2005 Generic Scan Tool 23 - Diesel Direct Fuel Injection System, Servicing .

Pump Injector Unit, Removing and Installing

Special tools, testers and auxiliary items required Dial gauge holder VW387 Socket insert 3410 Hex ball socket T10054 Extractor T10055 Torque wrench (5 to 50 Nm) VAG1331

Without illustration: Dial gauge Removing Remove upper toothed belt guard and cylinder head cover. Rotate crankshaft until cam pair of respective Pump-Injector Unit to be installed and removed face upward uniformly.

Loosen lock nuts of adjustment screws - 1 - and remove adjustment screws. Loosen mounting bolts - 2 - for rocker arm axle from outside to inside using socket insert 3410 and remove rocker arm axle. 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. Note the cylinder allocation of the Pump-Injector Units.

Insert extractor ( T10055 ) in place of tension block into lateral slot of Pump-Injector Unit. Using careful knocking motions, pull Pump-Injector Unit upward out of its cylinder head seat. Installing Note: For each step which requires an adjustment of Pump-Injector Unit, adjustment bolt in rocker arm and the ball pin for Pump-Injector Unit must be replaced. New Pump-Injector Units are shipped with O-rings and heat protection seal. If old Pump-Injector Unit is re-installed, the O-rings and heat protection seal must be replaced Pump Injector Unit O-Rings, Removing and Installing . Before installing Pump-Injector Unit, check that the three O-rings, heat protection seal and securing ring are seated properly. Note: O-rings must not be twisted on themselves. Oil O-rings and insert Pump-Injector Unit with great care into cylinder head seat. Drive Pump-Injector Unit in using uniform pressure into cylinder head seat until 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, mounting bolt can loosen and thereby cause damage to Pump-Injector Unit / cylinder head. Align Pump-Injector Unit as follows: 3

Screw in the new mounting bolt as far into tension block so that the Pump-Injector Unit can still be turned lightly. Align Pump-Injector Unit at right angle to thrust bearing of camshaft.

Using a caliper gauge (measuring range minimum 400 mm), check dimension "a" from outer edge of cylinder head to round surface of Pump-Injector Unit. Cylinder 1 2 3 4 Dimension a 333.0 0.8 mm 245.0 0.8 mm 153.6 0.8 mm 65.6 0.8 mm

Re-align Pump-Injector Unit if necessary and tighten mounting bolt as follows: Tighten securing bolt to 12 Nm plus an additional 270 degree (3/4 turn) (additional rotation can occur in several stages).

Install rocker arm axle and tighten new securing bolts as follows: First tighten inner bolts - 2 - , then outer bolts - 1 - uniformly hand-tight. Then in the same sequence, uniformly tighten to 20 Nm (44 ft lb) plus an additional 90 degree (1/4 turn).

Set dial gauge onto adjustment bolt of Pump-Injector Unit as shown. Rotate crankshaft in direction of engine rotation until rocker arm roller stands at camshaft point. Roller side ( - arrow A - ) stands at highest point Dial gauge ( - arrow B - ) stands at lowest point Remove dial gauge. Turn adjustment bolt into rocker arm until significant resistance is noticeable (Pump-Injector element stands at stop).

Turn back adjustment bolt from stop approx. 180 degree . Hold adjustment bolt in this position and tighten lock nut to 30 Nm. Connect connector to Pump-Injector Unit and install cylinder head cover and toothed belt guard.
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