Application: Read the warnings in paragraph 1 before starting work.
Attention! Under no circumstances should diesel fuel come into contact with the cooling system hoses - clean up any accidental leaks immediately. If the hose has been in contact with fuel for a long time, it must be replaced. The diesel fuel system is particularly sensitive to the penetration of non-dirt, air and water. Pay special attention to cleanliness when working on the fuel system. Wipe the area around it clean before disconnecting fuel system components. Store the removed components in a tightly closed container so that even condensate from the atmosphere does not accumulate in it. Use only a lint-free cloth for cleaning.
General information
1. Injectors under normal operating conditions should not require repair and replacement for about 100,000 km. Proper inspection, maintenance and adjustment of injectors must be carried out by a specialist. Defective injectors causing knocking or smoky exhaust can be found without removal as follows.
2. Start the engine and let it idle. Lay a rag around the fuel injector connections to collect the fuel. Disconnect the injectors one at a time by carefully unscrewing the union nuts. Loosening the nut on the defective injector will make the noise and smoke disappear.
Withdrawal
Note: Do not allow dirt to enter the fuel system during the operation. Do not drop the nozzles so as not to damage the locking needles. Nozzles are precision products that require delicate handling.
3. Cover the generator with a rag to wash it down with non-fuel.
4. Thoroughly clean the areas around the nozzles and connecting tubes. Disconnect fuel return hoses from injectors.
5. Wipe clean the pipe connections and loosen the nuts attaching them to the injectors, injection pump (tubes are removed in one piece). When loosening the connecting nuts on the injection pump fittings, hold the fittings with an open-end wrench so as not to unscrew them from the pump. Remove fuel pipes. Plug the pipes and fittings so that dirt does not get into the system.
6. Disconnect the wiring from the needle travel sensor on the No. 3 injector.
7. Loosen the nuts (or bolts) injector clamps. Remove washers, cybvbnt clamps and bushings (pic. 7.7, a-c).
8. Remove the injectors from the cylinder head (pic. 7.8). If the nozzles are tight, stir them up by turning the flats with an open end wrench. If this does not help, Audi applies "back" a hammer screwed to the threaded connection of the nozzle with the tube. Pay attention to that. that the second nozzle from behind is higher than the rest (third nozzle in 4-cylinder engines). It contains a needle lift sensor, which transmits a signal to the ECU of the engine.
9. Using a screwdriver, remove the copper flame arresters from the socket in the cylinder head. New washers are required for installation.
Installation
10. Carefully insert the nozzles into the sockets with new sealing washers. The nozzle with the needle lift sensor is installed in the third cylinder (pic. 7.10, a, b).
11. Install the mounting bushings and clamps, secure them with bolts (or nuts) with washers, tightening to the prescribed torque.
12. Connect the wiring to the third nozzle needle lift sensor.
13. Install stop beer pipes and tighten their union nuts to the prescribed torque.
14. Connect fuel return hoses to injectors.
15. Start the engine and check for normal operation.
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