Injector removal & installation: VW 2.3 (AZX)

🧭 Before you start

Fits: VW Passat B5 (3B)

Don't miss

• If fault is only detected alone, i.e. without Lambda probe or regulation faults, catalytic converter must be checked for damage and renewed if necessary.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Checking variable valve timing:
2. Checking variable valve timing solenoid valve: , final control diagnosis
3. Checking valve timing
4. Check air mass meter
5. Check air mass meter

6. Check intake system for leaks (unmetered air)
7. Check fuse 34
8. Check intake air temperature sender
9. Check coolant temperature sender
10. Check thermostat: Rep. Gr. 19; Removing and installing parts of cooling system; Parts of cooling system, engine-side
11. Checking Lambda probe ageing bank 1 Lambda probe 1
12. Checking Lambda probe and Lambda control after catalytic converter
13. Checking Lambda probe and Lambda control before catalytic converter
14. Checking Lambda probe and Lambda control after catalytic converter
15. Checking Lambda probe heating after catalytic converter
16. Checking Lambda probe and Lambda control after catalytic converter
17. Checking Lambda probe heating after catalytic converter
18. Checking fuel pressure regulator and holding pressure .
19. Checking injectors , checking quantity injected and checking for leaks
20. Check fuel pump: Rep. Gr. 20; Removing and installing parts of fuel supply system; Checking fuel pump
21. Check secondary air system for leaks: Rep. Gr. 26; Secondary air system
22. Checking hoses and connecting pipes to and between components: Rep. Gr. 26; Secondary air system
23. Check vacuum lines for leaks
24. Checking fuel pressure regulator and holding pressure .
25. Checking injectors , checking quantity injected and checking for leaks
26. Checking fuel pump:
27. Checking suction-jet pump: Rep. Gr. 20; Removing and installing parts of fuel supply system
28. Check intake system for leaks
29. Checking exhaust system for leaks: Rep. Gr. 26; Removing and installing parts of exhaust system
30. Check secondary air system for leaks: Rep. Gr. 26; Secondary air system
31. Check vacuum lines for leaks
32. Checking fuel pressure regulator and holding pressure .
33. Checking injectors , checking quantity injected and checking for leaks
34. Checking activated charcoal filter solenoid valve 1: Rep. Gr. 20; Activated charcoal filter system; Checking activated charcoal filter solenoid valve 1
35. Checking injectors .
36. Erase fault memory
37. Checking accelerator position sender: Rep. Gr. 20; Electronic engine output control (electronic throttle control); Checking accelerator position sender
38. Checking injectors .
39. Checking injectors .
40. Checking ignition cables and spark plugs
41. Checking ignition transformer
42. Checking misfiring detection
43. Checking engine speed sender
44. Checking knock sensors
45. Loosen knock sensor and tighten again to 20 Nm — 20 Nm (15 lb-ft)
46. Checking Hall sender
47. Checking secondary air pump motor: Rep. Gr. 26; Secondary air system
48. Checking combination valve: Rep. Gr. 26; Secondary air system
49. Checking secondary air injection valve: Rep. Gr. 26; Secondary air system
50. Checking hoses and connecting pipes to and between components: Rep. Gr. 26; Secondary air system
51. Checking Lambda probe and Lambda control before catalytic converter
52. Checking Lambda probe and Lambda control after catalytic converter
53. Checking Lambda probe ageing bank 1 Lambda probe 1 [Note: If fault is only detected alone, i.e. without Lambda probe or regulation faults, catalytic converter must be checked for damage and renewed if necessary.]
54. Checking activated charcoal filter solenoid valve 1 , final control diagnosis
55. Checking activated charcoal filter solenoid valve 1: Rep. Gr. 20; Activated charcoal filter system; Checking activated charcoal filter solenoid valve 1
56. Checking hoses and connecting pipes from fuel tank to throttle valve module: Rep. Gr. 20; Activated charcoal filter system; Checking activated charcoal filter system for leaks
57. Checking activated charcoal filter solenoid valve 1: Rep. Gr. 20; Activated charcoal filter system; Checking activated charcoal filter solenoid valve 1
58. Checking hoses and connecting pipes from fuel tank to throttle valve module: Rep. Gr. 20; Activated charcoal filter system; Checking activated charcoal filter system for leaks
59. Checking speed signal
60. Checking throttle valve control module

Other VW procedures

• Checking Lambda probe ageing of Lambda probe 1 before catalytic converter
• Checking Lambda probe ageing of Lambda probe after catalytic converter (adaptation)
• Checking signal from clutch pedal switch – VW Passat B5 2.3
• Checking signal from brake light switch and brake pedal switch
• Removing and installing fuel delivery unit: four-wheel drive vehicles
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures