Instructions: The following shows the removal and installation of injectors on the left bank of cylinders 2. Work stage on cylinder bank 1 only: remove the upper part of the air housing. filter together with an air flow meter. On cylinder bank 2, the coolant compensation tank must be unscrewed; the coolant lines remain connected.
Remove the engine cover. Mark the relationship between the injectors and the cylinder. Re-installation is only permitted on the same cylinder. When working with the injection system, observe cleanliness rules. Immediately close any open connections with a suitable cap. Remove the return line connections on the injectors by pressing both plates down and at the same time pulling the middle part upwards to unlock -arrow-.
Disconnect the plug connectors on the injectors to be removed. Loosen the union nuts of the high-pressure lines -1- using the insert -T40055- SW 17 on the injection modules. Loosen the union nuts of the high-pressure lines -2- using the socket SW17 -VAG 1331/6- on the ramp element.
Unscrew the injector caps -arrows-. Pull the covers up and turn them 90°.
Unscrew the injector clamps -arrows-.
Remove the injectors using a puller -T10055- with adapter -T10055/1 -. Place the removed injectors on a clean cloth.
Important instructions for installing injectors
The listed components and gaskets or seals. O-rings must be replaced every time they are removed or installed: "copper washer", "seal injector socket ring", "seal injector return ring". The following parts and seals, as well as seal. Replace the rings every time the injector is replaced: "clamp", "copper washer", "seal injector socket ring", "seal injector return ring". Everything is sealed. Before installation, lubricate the rings with mounting or oil. When reusing high-pressure lines, pay attention to the corresponding cylinder designations. The high pressure lines can be reused after the following checks. Check seal. cone of the corresponding high pressure line for the absence of deformations and cracks. The hole must not be deformed or damaged. Corroded lines should not be reused.
If a used injector is reinstalled
Treat the top of the injector with rust remover. After about 5 minutes, use a clean cloth to remove any rust or oil particles. If the nozzle is heavily soiled, clean its upper part additionally with a soft brass brush to facilitate removal of the copper seal (do not allow the brass brush to come into contact with the nozzle sprayer). To remove the old copper injector seal, carefully clamp it in a vice until it becomes stuck between the jaws when rotated. Using light rotational movements of your hand, remove the nozzle from the copper seal. Use a scraper to clean deposits under the copper seal. Using a plastic sleeve, install a new copper seal. To avoid damage to the seal. rings, place a new ring -2- on the fuel return fitting. line using the mounting rod -1 -. To remove rust particles from seals. On the surface of the injector, clean the injector seat in the cylinder head with a rag moistened with oil or rust remover. Do not damage the seal. surface.
Install the injectors. Tighten the union nuts of the high pressure fuel lines by hand. Make sure the installation is stress-free. Use a ratcheting torque wrench and socket wrench attachment -T40055- to tighten the high-pressure lines on the injectors.
For tightening high pressure lines to fuel. ramp, use a torque wrench with installation tool SW 17 -VAG 1331/6-. Observe the tightening torque.
Carefully install the return line fittings onto the injector through the lip seal (first check the lip seal for damage). Once the lock is latched, carefully push down the release bracket. After replacing one or more injectors, the engine control unit must be "adjustment of fuel quantity (IMA) " And "voltage adjustment (ISA) " for new injectors. Additionally, check all other injectors for "adjustment of fuel quantity (IMA) " And "voltage adjustment (ISA) " and the correctness of the specified adjustment values. If the correct correction values are available in the engine control unit, do not re-enter them under any circumstances.
Removing air from fuel. system and checking it for leaks
To remove air, do not open the high pressure terminals, air from the fuel. the system goes away on its own. Let the engine idle for a few minutes and then turn it off again. Turn off the ignition. Check the tightness of all fuel. return line systems and outlets (6 items). If there is a leak, despite the fact that the tightening torque has been observed, the corresponding component must be replaced. Replacement of return lines is carried out only in conjunction with a pressure reducing valve. Carry out a test drive over a distance of at least 20 km and, after performing at least one acceleration with a maximum load, check the high pressure area again for leaks. Presence of air in fuel. system during a test drive may cause the engine to operate in emergency mode. Turn off the engine and clear the fault memory. Continue test drive.
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