A defective injector can also be detected by loosening the union nuts while the engine is running at fast idle. If the engine speed does not change when a nut is loosened, this indicates a defect in the corresponding injector. The injector is checked with a pressure gauge (service station work).
Warning: Damaged nozzles must be replaced as they cannot be adjusted or repaired.
The first signs of a bad injector are:
- Defective ignition;
- Knocking in one or more cylinders;
- Engine overheating;
- Drop in engine power;
- Excessively black exhaust gases;
- High fuel consumption;
- Heavy blue smoke on cold start.
Withdrawal
1. Clean the high pressure lines with a cold cleaner.
2. Remove the high pressure pipes as a set by loosening the union nuts with an open ring wrench, eg HAZET 4560 or VW-3035.
Warning: Do not bend high pressure lines. Be sure to remove the pipeline as a set.
3. Loosen the injector mounting bolt, remove the clamp and remove the injector.
Warning: If it is difficult to dismantle the injector, you can use an impact extractor, for example, VW-3364 or HAZET 1966. An auxiliary tool is required to install the impact extractor, which is screwed onto the injector.
An auxiliary tool can be made as follows. Cut off the old high pressure pipe behind the union nut at a distance of about 5 cm. Solder the cut end with an M6 nut.
Warning: Clean the tool thoroughly. The ingress of dirt will cause the nozzle to fail!
4. Screw the auxiliary tool onto the injector in place and install the impact tool on the brazed nut. Pull out the nozzle.
5. Remove the heat seal.
Installation
6. Be sure to install new heat seals between the cylinder head and injector. The seal recess must point upwards, the arrow in the illustration points towards the cylinder head.
7. Insert the nozzle into place.
8. Install the injector clamp, making sure the support is in the correct position.
9. Insert the bolt with spherical washer and tighten with a torque of 20 Nm.
10. Secure the high pressure pipes with a torque of 25 Nm.
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