Checking injectors for break-off pressure and for leakage — VW
Checking injectors for break-off pressure and for leakage on VW: factory workshop procedure for engines ACV, AHY, AJT, AUF.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📐 20 workshop diagrams for ACV
Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.
📋 Procedure
ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.
AHY AJT AUF AXG AXL AYC
Engine code AJT
Note:
When the injector tester V.A.G 1322 is properly operated, a seemingly inadequate spray pattern will be observed during the following injection pressure test. However, the spray pattern test is not a diagnostic criterion for diesel injectors and by no means indicates a defect in the injector.
Checking break-off pressure
Special tools, testers, measuring instruments and auxiliary items required
Injector test unit V.A.G 1322 with pressure pipe V.A.G 1322/2
Connect injector to injector test unit.
Test conditions
Pressure gauge on
Warning!
When testing injectors ensure that the jet of fuel does not contact the hands as the high pressure will cause the fuel to penetrate the skin and may cause severe injuries.
Move pump lever down slowly. When spray begins, read off break-off pressure. For deviations from specification renew injector.
Specification: (bar)
New injectors: 220 ... 230 bar
Wear limit: 200 bar
Note:
When servicing used injectors adjust breaking pressures to specifications for new injectors.
Thicker shims increase breaking pressure.
Thinner shims decrease breaking pressure.
Increasing spring compression by 0.5 mm increases breaking pressure by 5.0 bar
Adjustment shims are available from 1.00...1.95 mm thick and increase by 0.5 mm. Use box 3065 to store shims.
Servicing injectors
Special tools, testers, measuring instruments and auxiliary items required
Torque wrench V.A.G 1332 (40 - 200 Nm)
Clamp upper part of injector in vice and loosen joint.
Clamp lower part of injector in vice before stripping further so that the individual parts do not fall out.
When dismantling the injectors ensure that all individual parts for an injector are kept together and are not interchanged with parts from other injectors.
Tightening torque:
Injector upper and lower parts: 60 Nm
Injector components
Fig. A: Injector with needle lift sender -G80-
Fig. B: Injector without needle lift sender
1 -
Injector lower part
2 -
Nozzle body
3 -
Nozzle valve (needle)
4 -
Intermediate disc
5 -
Pressure pin
6 -
Pressure pin
7 -
Nozzle valve spring
8 -
Shim
9 -
Injector upper part
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.