volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Adjusting non-contact gap of unit injectors > < Removing

Golf Mk5

Installing
Installing
  Note
t  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.
t  New unit injectors are supplied with O-rings and heat shield seal.
–  Heat shield seal and O-rings must be renewed if old unit injector is reused. → Chapter
–  Check that the 3 O-rings and the heat shield seal along with securing clip are seated correctly before installing unit injector.
  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 new securing bolt into clamping block, but do not tighten (it must still be possible to turn the unit injector slightly).
–  Now align unit injector at right angles to camshaft bearing seat.
   
–  Check dimension „a“ from outer edge of cylinder head to rounded edge of unit injector with a vernier gauge (measuring range at least 400 mm).
  N23-0419
CylinderDimension „a“
1333.0 ± 0.8 mm
2245.0 ± 0.8 mm
3153.6 ± 0.8 mm
465.6 ± 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 → Chapter.
  A15-0531

Adjusting non-contact gap of unit injectors > < Removing