Removing and installing injectors (solenoid valves) — VW

Removing and installing injectors (solenoid valves)
Special tools and workshop equipment required
Puller
T10055
Assembly sleeve
T10377
Puller
T10415
Removing
WARNING
Read rules for cleanliness and the instructions for working on the fuel system
Chapter
.
Always follow these rules for cleanliness and instructions before starting work and while working on the fuel system.
Caution
Mark allocation of injectors to cylinders. They must always be re-installed on the same cylinders.
Observe rules for cleanliness when working on the injection system.
The open connections must be sealed with a suitable cap.
Pull return line connections off injectors. To do this, press the catches
1
and
2
downwards and, at the same time, pull the release pin upwards
arrow
.
Detach connectors
arrows
from injectors.
Caution
When releasing high-pressure line, counterhold high-pressure connection using an open-ended spanner. Leaks occur if high-pressure connection is released.
Unscrew union nuts of relevant high-pressure line
1 to 4
and remove corresponding high-pressure line.
Unscrew bolt
1
of the clamping piece of the injector that is to be removed.
Fit
puller
T10055
with puller
T10415
and pull injector out upwards using tapping movements.
Note
Pull injector out using rotary movements in order not to damage sealing lip.
Place the removed injectors on a clean cloth.
Installing new injectors
When a fitting a new injector, the following must be replaced:
Copper seal
O-ring 3 for shaft of injector
O-ring for fuel return connection
Note
Observe cylinder specific markings when reusing high-pressure lines.
The high-pressure lines may be re-used after the following checks:
Check taper seat of respective high-pressure line for deformation and cracks.
The line hole must not be deformed, constricted or damaged.
Corroded lines should no longer be used.
Installing used injectors
When a used injector is re-fitted, the following must be replaced:
Copper seal
O-ring 3 for shaft of injector
O-ring for fuel return connection
Spray tip of injector with an rust removal spray. Wait approx. 5 minutes and wipe off soot and oil particles with a cloth.
If an injector is very dirty, the tip of the nozzle should also be cleaned with a soft brass wire brush to make it easier to remove the copper seal. Do not apply the wire brush to the bores in the nozzle.
To remove the old copper seal from the injector, clamp the seal carefully in a vice so that it is just held between the jaws without turning. Then carefully pull and twist the injector out of the copper seal by hand.
Use a scraper to clean off the deposits under the copper seal.
Clean sealing surface of injector in cylinder head and injector shaft.
WARNING
Only
cleaning set
VAS 6811
may be used for cleaning sealing surface of injector bore.
For detailed information on how to use the cleaning set as well as the order in which its components are applied, refer to the
operating manual
provided with the
cleaning set
VAS 6811
.
Replace O-ring for shaft of injector. Use
assembly sleeve
T10377
to do this.
Install injectors.
Note
If any of the seals for injectors in cylinder head cover are damaged, replace the affected seal .
Tighten union nuts of high-pressure lines hand-tight. Check they are seated without stress.
Tighten high-pressure lines to specified torque.
Press return line connections carefully over the seals and onto the injectors (first check seal for damage). The catch should engage audibly. Then press release pin down carefully.
After one or more injectors have been renewed, the correction values for the new injectors must be entered into the engine control unit
Vehicle diagnostic tester
.
Also check all the other injectors to find out whether the correct correction values have been stored in the engine control unit. Do not attempt to re-enter these values if the correct values are already stored in the engine control unit.
Note
The high-pressure connections must not be opened for bleeding.
Start engine and run at idling speed for a few minutes, then switch off again.
Switch off ignition.
Check the complete fuel system and return line connections for leaks
Chapter
.
Renew the affected component if leakage still occurs after tightening to the correct torque.
Note
The return lines can only be renewed complete.
Then, road-test the vehicle for more than 20 km. Accelerate with full throttle at least once. Then, check high-pressure system again for leaks.
Note
If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Stop engine and delete event memory
Vehicle diagnostic tester
. Then continue the road test.
Specified torques
Chapter
“
Assembly overview - fuel system
”