Fuel Injectors, Removing and Installing

Injectors, Removing And Installing

Recommended special tools and equipment
- VAG1331 torque wrench (5 to 50 Nm)
- 3035 Injector line wrench

NOTE:
Malfunctioning injectors cause the following malfunctions:
- Rough engine idle
- Diesel knock
- Knocking in one or more cylinders
- Engine overheating
- Loss of performance
- Excessive black exhaust smoke
- High fuel consumption
- Excessive blue smoke during cold start

Malfunctioning injectors can be located by loosening the injector line union nuts on each injector in sequence, with the engine running at a fast idling speed. If the engine speed remains constant after loosening an injector line union nut, this indicates a malfunctioning injector.

Removing
- Remove injectors lines using 3035 injector line wrench.

NOTE: Always remove wiring set completely. Do not change bend-shape.

- Loosen securing bolt, remove tension bracket and injector.
- Cover openings with a clean rag.

Installing

NOTE: Always replace the heat protection seal between cylinder head and injectors.


- Insert injectors.
- Be sure mounting brackets are properly seated in cylinder head.
- Insert tension bracket.

Tightening torques:
Injector lines = 25 Nm
Tension bracket bolt = 20 Nm

- Erase DTC memory of control module for Diesel-Direct fuel injection system, Diagnostic mode 4: Reset/erase diagnostic data.
- Generate readiness code.