Volkswagen Golf / Golf Plus. Manual - part 333

 

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Volkswagen Golf / Golf Plus. Manual - part 333

 

 

– Pull unit injector out of cylinder head seat with gentle upward

taps.

1.4.2

Installing

Note

Each time work is performed which requires adjustment of the

unit injector, the adjustment screw in the rocker arm and also

the unit injector ball stud must be renewed.

New unit injectors are supplied with O-rings and heat shield

seal.

– Heat shield seal and O-rings must be renewed if old unit in‐

jector is reused. 

⇒ page 172

– Check that the three O-rings and the heat shield seal along

with securing clip are seated correctly before installing unit in‐

jector.

Note

The seals must not be twisted.

– Oil the seals and fit the unit injector into the seat in cylinder

head with great care.

– Push the unit injector evenly into the cylinder head onto its limit

stop.

– Insert tensioning block in slot on side of unit injector.

Note

If the unit injector is not at right angles to the tensioning block the

securing bolt may loosen and this can damage the unit injector or

the cylinder head.

– Therefore align the unit injector as follows.
– Screw the new securing bolt into the tensioning block until the

unit injector can still be turned easily.

– Now align unit injector at right angles to camshaft bearing seat.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

170

     Rep. Gr.23 - Mixture preparation - injection

 

range min. 400 mm).

Cylinder

Dimension “a”

1

333,0 ± 0.8 mm

2

245,0 ± 0.8 mm

3

153,6 ± 0.8 mm

4

65,6 ± 0.8 mm

– If necessary, adjust the unit injector and tighten the securing

bolt as follows:

– Tighten securing bolt to 12 Nm and turn 270° (3/4 turn) further

(turning further can be done in several stages).

– Fit rocker arm shaft and tighten new securing bolts as follows:
– First evenly tighten inner bolts -2- and then outer bolts -1-

hand-tight. Then using same sequence, tighten to 20 Nm and

90° (1/4 turn) further evenly.

– Adjust non-contact gap of unit injectors 

⇒ page 171

 .

1.5

Adjusting non-contact gap of unit injec‐

tors

– Fit dial gauge onto adjustment screw of unit injector as shown.
– Turn crankshaft in direction of engine rotation until roller of

rocker arm is located at tip of drive cam. Roller side

-arrow A- positioned at highest point, dial gauge -arrow B-

positioned 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 adjustment screw 180° back off stop.
– Hold adjuster screw in this position and tighten lock nut to 30

Nm.

– Connect unit injector connector.
– Install cylinder head cover 

⇒ page 48

 .

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Diesel direct injection system    

171

 

injector

Special tools and workshop equipment required
♦ Assembly sleeves -T10056-

1.6.1

Removing

– Lever old O-rings very carefully out of unit injector.
– Ensure above all that no burrs are formed on O-ring seat.

1.6.2

Installing

Note

Always use the assembly sleeves to fit the O-rings. There is a

danger of damaging the O-rings if the sleeves are not used.

Gradual introduction of O-rings without different coloured

markings. Note the correct allocation of O-rings to grooves:

the thickness of the rings reduces towards injector nozzle.

Prevent O-rings from rolling when sliding them on. The O-rings

must not be twisted in their seats in unit injector.

– Pull heat shield seal off together with securing clip.
– Clean seating surfaces for O-rings on unit injector very care‐

fully.

– Place assembly sleeve -T10056/1- onto stop on unit injector.
– Push the upper, thicker O-ring carefully onto assembly sleeve

and into seat on unit injector.

– Remove assembly sleeve.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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     Rep. Gr.23 - Mixture preparation - injection

 

– Remove assembly sleeve.

– Place assembly sleeve -T10056/3- onto stop on unit injector.
– Push the lower O-ring carefully onto the assembly sleeve and

into the seat of the unit injector.

– Remove assembly sleeve.
– Fit new heat shield seal together with securing clip.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Diesel direct injection system    

173

 

 

 

 

 

 

 

 

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