Skoda Workshop Service and Repair Manuals

Removing and installing the unit injector Special tools and workshop equipment required t  Extractor -T10055- t  Universal dial gauge holder -MP 3-447- t  Dial gauge t  Torque wrench   Note

On vehicles with WIV the adjusting screw -1- and the ball pin -2- was changed On old engines with WIV, both variants can be combined. Removing –  Remove upper timing belt cover and cylinder head cover → 1.4/51; 55; 59 TDI Engine, Mechanics; Rep. Gr.15. –  Rotate the crankshaft approx. in the TDC cylinder 1, while doing so all valve levers must point upwards evenly.

–  Release the counternuts of the adjusting screws -1- and unscrew the adjusting screws until the relevant valve lever rests against the tappet spring of the unit injector. –  Screw out fixing screws -2- for the valve-lever shaft from the outside to the inside and remove the valve-lever shaft. –  Separate plug connection at the removed unit injector. Support the opposite side of the connector with your finger in order to avoid twisting the connector. –  Screw out fixing screw -3- of the clamping pad and remove the pad in the direction towards the camshaft.   Note When removing all unit injectors turn the engine so that the outlet cam for cylinder 1 (the first one from the belt pulley side) points with the tip upwards. All three clamping pads can be removed in this position.

–  Insert the extractor -T10055- instead of the clamping pad in the slot of the unit injector. –  Remove the unit injector through movements of the sleeve at the nut up to the stop in -direction of arrow-.   Note Do not interchange the unit injectors, if necessary mark the assignment to each cylinder. Installing   Note t  The associated adjusting screw in the valve-lever should be replaced when a new unit injector is being installed. t  For any work procedure involving an adjustment of the unit injector it is necessary to clean the adjusting screw in the valve lever and also the ball pin of the unit injector and to check them for traces of wear. If there is any wear replace the ball pin and the adjusting screw. t  Grease the contact surfaces between the ball pin and the adjusting screw using -G 000 100-. t  New unit injectors are supplied with O-rings and heat-protection seal. t  Before installing again the original unit injector, O-rings, heat-protection seal and circlip must be replaced. –  Before installing the unit injector check the correct position of the three O-rings, heat-protection seal and the circlip.   Note The O-rings must not be twisted. –  Oil the O-rings and place the unit injector with the greatest of care into the cylinder head. –  Slide the unit injector into the cylinder head seat up to the stop by exerting a uniform pressure. –  Place the clamping pad in the side slot of the unit injector.   Note If the unit injector is not perpendicular to the clamping pad the fixing screw may loosen and cause damage to the unit injector or cylinder head. –  Align the unit injector as follows: –  Screw the clamping pad with the new fixing screw until the unit injector can still easily be turned. –  Set the unit injector at a right angle to the bearing shell of the camshaft. –  Using a caliper gauge, check dimension -a- from the outer side of the cylinder head to the cylinder surface of the solenoid valve for the unit injector.

Removing and installing the unit injector with the old solenoid valve nut

Cylinder	Dimension -a-
1	244,2 ± 0.8 mm
2	156,2 ± 0.8 mm
3	64,8 ± 0.8 mm

Removing and installing the unit injector with the new solenoid valve nut

Cylinder		Dimension -a-
1		245,0 ± 0.8 mm
2		157,0 ± 0.8 mm
3		65,6 ± 0.8 mm

–  Adjust the unit injector as required, tighten the fixing screw using a torque of 12 Nm and then turn through a further 270° (3/4 of a turn). Tightening may occur in successive stages. –  Mount valve-lever shaft and tighten up the new fixing screws as follows. –  First tighten the inside screws and then the two outside screws by hand. In the same sequence tighten to 20 Nm and turn a further 90° (1/4 turn).

–  Place a dial gauge on the adjusting screw of the unit injector. –  Turn the crankshaft in the running direction of the engine until the roller of the valve lever is on the drive cam tip. t  Roller side -arrow A- is on the highest point. t  Dial gauge -arrow B- is on the lowest point. –  Remove the dial gauge. –  Turn the adjusting screw in the valve lever until one feels a significant resistance (the unit injector is against the stop).

–  Turn the adjusting screw in the opposite direction from the stop by about 225 ° (5/8 turn) –  Firmly hold the adjusting screw in this position and tighten up the lock nut using a torque of 30 Nm. –  Place connector onto the unit injector, install the cylinder head cover and insert the upper timing belt cover.