Engines 1.9-I-110 HP/2.5-I-TDI
Serviceability and correct adjustment of injectors are very important for the normal operation of the engine. If the nozzle atomizer does not provide the desired shape of the flame or a bad cutoff occurs, the engine starts to work with vibration, strong mechanical knocks appear, and smoke increases.
To determine a faulty injector, you need to make sure that the engine is working and the compression level is the same in all cylinders.
Start the engine and warm it up to normal operating temperature.
Loosen the fuel line union nut on the injector to be checked. Note if the engine speed has changed.
With a good fuel injector, there will be a clear decrease in engine speed, accompanied by its uneven operation. If the injector being checked is faulty, the change in engine speed will be insignificant and, if present, an extraneous knock will disappear.
Faulty injectors must be replaced, as they cannot be repaired.
The presence of a faulty fuel injector is indicated by the following deviations in engine operation:
- reduction in engine power;
- blue smoke when starting a cold engine;
- thick black smoke comes out of the exhaust pipe;
- increased fuel consumption;
- engine overheating;
- knocking in one or more cylinders;
- cylinder misfires.
Withdrawal
Clean the area around the fuel injectors and fuel line union nuts.
Using a HAZET 4 560 or VW-3035 wrench, unscrew the union nuts and remove the high pressure fuel lines as a set (see fig. 4C.7).
Unscrew the pipelines connecting the nozzles.
Engine V6 2,5-I-TDI. Remove the cylinder head cover.
Unscrew the fuel injector holders and remove the fuel injectors from the engine (see fig. 4C.8).
Engine 1.9-I-TDI.Injectors stuck in the engine can be removed using an AUDI 3364 or Hazet 1966 impact tool (see fig. 4C.9).
Engine V6 2.5-I-TDI
Manual Transmission.If the camshaft lobe is preventing injector removal, shift to fourth gear. When moving the car, rotate the engine to a position where the camshaft cam does not interfere with the removal of the injector.
Automatic transmission. If the camshaft cam is preventing the injector from being removed, screw the injector holders back into place. Connect the connectors to the fuel pump. Turn the crankshaft of the engine with a starter so that the camshaft cam does not interfere with the removal of the nozzle.
Remove the thermal sealing ring.
Installation
When installing fuel injectors, a new thermal O-ring must be used.
Install fuel injectors.
Install nozzle holders. Tighten the retainer nuts on the 1.9-I-TDI engine to 20 Nm and on the V6 2.5-I-TDI engine to 10 Nm.
Engine V6 2,5-I-TDI.Install the cylinder head cover and tighten the fastening nuts to 10 Nm.
Establish the pipelines connecting atomizers.
Install the high pressure fuel lines and screw on the union nuts, tightening them on the 1.9-I-TDI engine to 30 Nm and on the V6 2.5-I-TDI engine to 25 Nm.
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