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    Removing and Installing Unit Injectors

    Uploaded by

    Diana Silva
    This document provides instructions for removing and installing unit injectors on diesel engines. Special tools are required, including pullers, wrenches, and dial gauges. To remove an injector, the cylinder head cover must be taken off and the crankshaft positioned correctly. Electrical connectors are detached and retaining bolts are loosened. A puller is used to lift the injector out of the cylinder head. When installing, O-rings must be checked and lubricated before carefully pressing the injector into place. Securing bolts are tightened in stages using a torque wrench and wrench. Adjustment is performed using a dial gauge to set clearance between the rocker arm and injector.

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    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd

    Removing and Installing Unit Injectors

    Uploaded by

    Diana Silva
    234 views9 pages
    This document provides instructions for removing and installing unit injectors on diesel engines. Special tools are required, including pullers, wrenches, and dial gauges. To remove an injector, the cylinder head cover must be taken off and the crankshaft positioned correctly. Electrical connectors are detached and retaining bolts are loosened. A puller is used to lift the injector out of the cylinder head. When installing, O-rings must be checked and lubricated before carefully pressing the injector into place. Securing bolts are tightened in stages using a torque wrench and wrench. Adjustment is performed using a dial gauge to set clearance between the rocker arm and injector.

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    TDI PD

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    This document provides instructions for removing and installing unit injectors on diesel engines. Special tools are required, including pullers, wrenches, and dial gauges. To remove an injector, the cylinder head cover must be taken off and the crankshaft positioned correctly. Electrical connectors are detached and retaining bolts are loosened. A puller is used to lift the injector out of the cylinder head. When installing, O-rings must be checked and lubricated before carefully pressing the injector into place. Securing bolts are tightened in stages using a torque wrench and wrench. Adjustment is performed using a dial gauge to set clearance between the rocker arm and injector.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    234 views9 pages

    Removing and Installing Unit Injectors

    Uploaded by

    Diana Silva
    This document provides instructions for removing and installing unit injectors on diesel engines. Special tools are required, including pullers, wrenches, and dial gauges. To remove an injector, the cylinder head cover must be taken off and the crankshaft positioned correctly. Electrical connectors are detached and retaining bolts are loosened. A puller is used to lift the injector out of the cylinder head. When installing, O-rings must be checked and lubricated before carefully pressing the injector into place. Securing bolts are tightened in stages using a torque wrench and wrench. Adjustment is performed using a dial gauge to set clearance between the rocker arm and injector.

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    Removing and installing unit injectors

    Special tools and workshop equipment required


    Universal dial gauge bracket -VW 387 Socket -3410 Special wrench (long reach) -T10054 Tool set for FSI engines -T10133 Torque wrench -V.A.G 1331 Puller -T10163-

    Valve lever -VW 541/1 Awith press tool for VW 541


    / 1 A and 2037 -VW 541/5-

    Assembly device for


    valves -2036-

    Dial gauge -VAS 6079-

    Removing
    Remove cylinder head

    cover Rep. Gr.15.


    Turn crankshaft until both
    cams on cylinder of unit
    injector to be removed
    point symmetrically
    upwards. To do so:
    Vehicles with manual
    gearbox: push vehicle
    forwards with 4th gear
    engaged and ignition
    switched off.
    Vehicles with multitronic
    gearbox: remove noise
    insulation, remove torque
    reaction support and stop
    for torque reaction support,
    lever off cover cap from
    vibration damper and
    rotate crankshaft in
    clockwise direction via
    central bolt for vibration
    damper.
    Loosen the lock nuts -2- of
    the adjuster screws -1- on
    all unit injectors.
    Unscrew the adjuster
    screws until each rocker

    arm touches the tappet


    spring of the unit injector.
    Unscrew bolts -1, 3, 5
    using socket -3410-.
    Unscrew bolts -2- and -4using socket -3410
    alternately in several
    stages.
    Note
    Do not pull bolts out of rocker
    arm shaft so that components
    remain attached to shaft. If
    necessary mark position on
    rocker arm.
    Detach rocker arm shaft.

    Detach electrical
    connectors from glow

    plugs -A- and from unit


    injectors -B-.
    Caution
    Only slacken or tighten the
    bolts at the retaining clips
    when removing and
    installing unit injectors. If
    the electrical wiring harness
    is released at the retaining
    clips, the clips will become
    bent and this may lead to a
    break in the wiring because
    of the increased amount of
    play.
    Remove bolts -arrows- at
    retaining clips and move

    entire electrical wiring


    harness clear to one side.
    Unscrew bolts -arrows with special wrench (long
    reach) -T10054-.

    Pull out ball stud -1- from


    unit injector to be removed.

    Insert puller -T10163- in


    bolt holes on unit injector.
    Turn spindle -A- down
    lightly onto the unit

    injector. Hand-tighten lock


    nut -B-.
    By tapping gently with
    screw striker -T10133/3-,
    lift the unit injector
    upwards out of its seat in
    the cylinder head.

    Note
    Mark cylinder numbers of unit
    injectors for re-installation.
    Installing and adjusting
    Note
    Renew bolts on unit

    injectors.
    Before installation oil O rings and guide in cylinder
    head.
    New unit injectors are

    supplied with new O-rings.


    When installing a new unit
    injector, you must also
    renew the appropriate
    adjuster screw in rocker
    arm.
    When re-installing the old
    unit injector, you must

    replace the O-rings


    Chapter.
    Whenever an operation
    requires adjustment of a
    unit injector, the adjuster
    screw in the rocker arm
    and the ball stud of the
    unit injector must be
    cleaned and examined for
    signs of wear. Ball stud
    and adjuster screw must
    be renewed if signs of
    wear are found.
    Grease the contact
    surfaces between the ball
    stud and adjuster screw
    with lubricating grease -G
    000 100-.
    Before installing unit
    injector check that both Orings are properly seated.
    The O-rings must not be

    twisted.
    The O-ring marked white
    is located in the lower
    groove on the unit injector.

    Lubricate seals and body


    of unit injector.
    Check seat of unit injector
    in cylinder head for dirt
    and any foreign particles
    (metal shavings/carbon
    etc.) and blow out with
    compressed air if
    necessary.
    Insert unit injector very
    carefully into cylinder
    head seat.
    Fit valve assembly device
    -2036- with securing
    plates -2036/1- onto
    retaining frame of cylinder
    head as shown.

    Caution
    If the unit injector is pulled
    down by the securing bolts,
    there is a danger that the
    unit injector will be drawn
    into its seat at an angle.
    This may subsequently lead
    to engine running problems
    and starting problems. For
    this reason the unit injector
    must be pressed into its
    seat first and may be
    tightened only then.
    Insert new securing bolts
    and carefully screw in by
    hand without applying
    force until they make
    contact -arrow-.

    Then fit valve lever -VW


    541/1 A- using press tool
    -VW 541/5-.
    Carefully press unit
    injector into its seat using
    valve lever -VW 541/1 Awhile keeping the force
    applied.
    Then screw in securing
    bolts for unit injector by
    hand without applying

    force using special wrench


    (long reach) -T10054- until
    they make contact.

    Tighten bolts for unit


    injectors -arrows- as
    follows:

    1. Tighten with torque wrench to 3 Nm.


    2. Turn 90 (1/4 turn) further using a rigid wrench.
    3. Turn 180 (1/2 turn) further using a rigid wrench.

    Before inserting rocker arm


    shaft, check whether all
    ball studs -1- and O-rings
    -2- have been installed in
    unit injectors.

    Secure the rocker arm


    shaft as follows:

    Tighten bolts -2- and -4- alternately in several stages until rocker arm shaft lies on bearing
    frame.
    2. Tighten bolts -1-, -3- and -5- to 20 Nm + 90 (1/4 turn).
    3. Tighten bolts -2- and -4- to 20 Nm + 90 (1/4 turn).
    1.

    Apply dial gauge -VAS


    6079- to adjuster screw of
    unit injector, as shown in
    illustration.
    Turn crankshaft in
    direction of engine rotation
    until roller of rocker arm is
    located at tip of drive cam.
    Roller side -arrow A- is at
    highest point.
    Dial gauge -arrow B- is at
    lowest point.
    Remove dial gauge.
    Now turn the adjuster
    screw into rocker arm until
    significant resistance can
    be felt (unit injector is at
    limit stop).

    Turn adjuster screw 180


    back off stop.
    Hold adjuster screw in this
    position and tighten lock
    nut to 30 Nm.
    Perform further installation in
    reverse order, paying
    attention to the following:
    Install cylinder head cover

    Rep. Gr.15.

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