Fuel Injectors, Removing and Installing

WARNING! Fire Hazard! Do NOT have anything in the area that can ignite Diesel fuel!


Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
- VAG 1331 torque wrench, 5 to 50 Nm (3.7 to 37 ft lb)







- 3035 Offset tubing wrench







NOTE: Faulty injectors can cause the following malfunctions:


- Misfiring
- Knocking in one or more cylinders
- Engine over-heating
- Loss of power
- Excessive black exhaust smoke
- Higher fuel consumption
- Excessive blue smoke when starting from cold


NOTE: Faulty injectors can be located by loosening the high pressure pipe union on each injector in sequence with engine running at fast idle. If engine speed remains constant after loosening a pipe union, this points to a faulty fuel injector


Removing

- Remove injection lines using 3035 tubing wrench.


NOTE: Always remove injector line cluster complete. Do not alter line shape.


- Remove mounting nut, take off retainer and remove injector.

Installing


NOTE: Always replace the heat shield between the cylinder head and the Diesel fuel injector


- Insert fuel injector.
- Ensure that mounting is seated correctly in cylinder head.
- Install retainer.

Tightening torques:
- Injection lines = 25 Nm (18 ft lb)
- Retaining nut = 20 Nm (15 ft lb)