Table of contents: Engines 1.9-I-110 hp/2.5-I-TDI ↓ V6 2.5-I-TDI engine ↓
Engines 1.9-I-110 hp/2.5-I-TDI
The serviceability and correct adjustment of the injectors are very important for the normal operation of the engine. If the injector spray does not provide the required torch shape or there is a bad cut-off, the engine begins to vibrate, strong mechanical knocks appear, and smoking increases.
To determine a faulty injector, you need to make sure that the engine is in good condition 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 nipple nut on the injector being tested. Note whether the engine speed has changed.
If the fuel injector is in good condition, there will be a clear decrease in engine speed, accompanied by uneven operation. If the injector being tested is faulty, the change in engine speed will be insignificant and the extraneous knocking noise will disappear if it was present before.
Defective injectors must be replaced, as they cannot be repaired.
The following deviations in engine operation indicate the presence of a faulty fuel injector:
- engine power reduction;
- 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.
Removal
Clean the area around the fuel injectors and fuel line union nuts.
Using the HAZET 4 560 or VW-3035 key, unscrew the connecting nuts and remove the high-pressure fuel lines as a set (see Fig. 4C.7).
Unscrew the pipes connecting the injectors.
V6 2.5-I-TDI engine. 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 the AUDI 3364 or Hazet 1966 impact tool (see Fig. 4C.9).
V6 2.5-I-TDI engine
Manual transmission.If the camshaft lobe prevents the injector from being removed, engage fourth gear. While moving the vehicle, rotate the engine to a position where the camshaft lobe does not prevent the injector from being removed.
Automatic transmission. If the camshaft lobe prevents the injector from being removed, screw the injector holders back into place. Connect the connectors to the fuel pump. Turn the engine crankshaft with the starter so that the camshaft lobe does not prevent the injector from being removed.
Remove the heat-protective sealing ring.
Installation
When installing fuel injectors, a new heat-protective sealing ring must be used.
Install the fuel injectors.
Install the injector holders. Tighten the holders mounting nuts on the 1.9-I-TDI engine to 20 Nm, and on the V6 2.5-I-TDI engine to 10 Nm.
V6 2.5-I-TDI engine.Install the cylinder head cover and tighten the mounting nuts to a torque of 10 Nm.
Install the pipes connecting the injectors.
Install the high-pressure fuel lines and tighten the union nuts to 30 Nm on the 1.9-I-TDI engine and 25 Nm on the V6 2.5-I-TDI engine.
This article was copied from an online resource audimanual