Removing
Remove engine cover. Remove the noise insulation from the cylinder head cover. Disconnect connectors -1- from injectors to be removed.
Disconnect the fuel return line fittings from the removed injectors. To do this, press the fitting down by the tabs and pull the middle part upwards to unlock it.
Instructions: It is necessary to monitor the maintenance of cleanliness, to prevent dirt from entering the removed fuel return lines and injector connectors.
Remove the high pressure pipe between the rail and the nozzle to be removed. Unscrew the screws securing the cover of the removed nozzle. Lift the cap slightly and then turn it 90°to gain access to the nozzle mounting nuts.
Caution: If the injector fastening nuts are carelessly loosened or tightened, there is a high probability that they will fall inside the cylinder head. Therefore, this operation must be carried out with the utmost care so as not to carry out unplanned assembly work and to avoid subsequent damage to the engine.
Unscrew the fastening nuts of the respective injector. Position puller -T10055- with adapter -T10055/1- as shown in illustration and pull injector out of its socket with light blows.
Installation
Important instructions to follow when installing injectors.
The following components and gaskets or O-rings must be replaced each time they are removed and installed: "pressure plate", "copper washer" "injector seat sealing ring" "injector drain seal". When installing a new injector, the following parts and seals or O-rings must be replaced: "pressure plate", "injector line", "copper washer", "nozzle seal ring", "injector return seal". When reinstalling the injectors, they must only be installed in their own place (cylinder). Before installation, check the cleanliness of the nozzles and seats. The injectors must not show any damage. Lubricate all O-rings with assembly or engine oil before installation.
The procedure for installing a new (used) nozzles
Apply a rust remover to the nozzle tip (from an aerosol can). After five minutes, remove soot and oil particles with a rag. To remove the old copper sealing ring of the injector, carefully clamp it in a vise so that the injector itself can be rotated between the jaws of the vise. With light rotational and translational movements, remove the nozzle from the copper sealing ring. Install a new copper o-ring with a plastic bushing. To avoid damage to the new rubber sealing ring -2- of the fuel return connector, it must be installed by sliding it along the mounting rod -1-. To remove soot particles from the seating surface, clean the injector well in the cylinder head with a rag soaked in engine oil or a rust remover. Do not damage the seating surface while doing this.
Replace O-ring for injector chamber using tool -T10377-. Install nozzle cover. Place the pressure plate on the injector in the correct mounting position. Insert the nozzle into the cylinder head well.
Caution: If the injector fastening nuts are carelessly loosened or tightened, there is a high probability that they will fall inside the cylinder head. Therefore, this operation must be carried out with the utmost care so as not to carry out unplanned assembly work and to avoid subsequent damage to the engine.
Being careful, hand-tighten the pressure plate mounting nuts, and then tighten them. Turn the nozzle cover into the installation position and fix it with screws. Install high pressure lines.
Instruction: When replacing one or more injectors, the engine control unit must record "quantity correction value (IMA) " And "voltage correction value (ISA) " for new injectors.
Installation of high pressure lines
Caution: For the best and stress-free installation of the injection lines, loosen the fuel rail and a little dare. Pipelines must never be bent or stretched. This would eventually lead to a break in the corresponding line.
Instructions: Below is a description of the installation of new injection lines. When re-installing previously used injection lines, they should be checked according to the above paragraphs. The procedure in both cases is identical.
Installation of individual injection lines (cylinder between fuel rail and injector)
Remove the packaging of the new injection line, remove the plugs and immediately install the line between the fuel rail and the injector. First tighten the union nuts of the injection pipes by hand without tools. Make sure that the line is properly in place. Carry out, if necessary, similar operations with other injection lines. Tighten the fuel rail again if necessary. Tighten union nuts of all newly installed injection lines with torque wrench -VAG 1331- and socket -T40055-.
Fuel line installation (between injection pump and fuel rail) or the whole set of highways
Disconnect, if not previously done, the fuel rail mounting bolts and check for wear. Then remove the packaging from the fuel line between the injection pump and the fuel rail, remove the plugs and immediately install the line. First tighten the union nuts of the injection pipes by hand without tools. Make sure that the line is properly in place. Carry out, if the entire kit is installed, similar actions with four injection lines. Mount all three mounting clamps above the fuel line, make sure that they are aligned. Screw in the clamp bolts about 3 turns. Tighten the fuel rail again. Tighten upper retaining clip on intake manifold to 8 Nm.
Tighten union nuts of all newly installed injection lines with torque wrench -VAG 1331- and socket -T40055-. Tighten the remaining two clamps to 8 Nm. Carefully push the fittings of the fuel return lines onto the O-rings of the injectors (check them for damage first). The fitting should engage with a distinctly audible click. After that, you need to gently push down the latches. Refuel the system.
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