Volkswagen Golf Variant / Jetta. Manual - part 433

 

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Volkswagen Golf Variant / Jetta. Manual - part 433

 

 

Refer to the Parts Catalog.
-B-, With ribbing: for connecting the overflow oil line, do NOT use

a clamp

3.4

Fuel Injector (Piezo Injector), Removing

and Installing

Special tools and workshop equipment required
♦ Puller - Unit Injector - T10055- with Puller - Unit Injector Adapt‐

er 1 - T10055/1-

♦ O-Ring Assembly Sleeve - T10377-
♦ Union Nut Socket - T40055-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1331 Insert - Reversible Ratchet -

VAG1331/1-

DANGER!

♦ Follow the safety precautions when working on the diesel

direct fuel injection system. Refer to

⇒ “1 Safety Precautions when Working on Diesel Direct

Fuel Injection System”, page 303

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 305

 .

Always pay attention to these instructions before and during

work.

Removing:
– Remove the engine cover. Refer to

⇒ “1.4 Engine Cover, Removing and Installing”, page 90

 .

– Remove the protective strip, if equipped -item 1-

⇒ Item 1 (page 312)

 .

3. Diesel Direct Injection System    

315

moved.

– Before removing, dry the return line connection on the fuel in‐

jectors that will be removed (for example using a commercially

available detergent).

– Clean and dry the return line connections.
– Cover the return line connection with a rag.

– Remove the fuel return line connections -1- from the fuel in‐

jectors to be removed. Pull them upward to release.

Note

Pay attention to cleanliness. Dirt and contaminants must not enter

the return lines and the connections on the fuel injectors.

– Remove the high pressure line -item 5- 

⇒ Item 5 (page 312)

between the rail element (high pressure reservoir) and the fuel

injectors to be removed.

– Remove the bolts in the cover -item 18-

⇒ Item 18 (page 313)

 on the fuel injectors to be removed.

– Raise the cover slightly and rotate it 90° to free up the fuel

injector nuts.

Caution

When removing the fuel injector nuts, the nut could fall into the

cylinder head. Work very carefully to avoid unnecessary work

or damage.

– Remove the nuts from the corresponding fuel injector.

316

Unit Injector - Adapter 1 - T10055/1- , as shown, and remove

the fuel injector upward by tapping.

Installing:
Important Instructions on Installing the Fuel Injectors:
• The following components, seals and O-rings must be re‐

placed during every removal and installation: “tensioning claw”

“copper washer”, “O-ring from the fuel injector shaft” and the

“O-ring for the fuel injector return”.

• The following components, seals and/or O-rings must be re‐

placed when replacing an injector: “tensioning bracket”, “in‐

jection line”, “copper washer”, “injector shaft O-ring” and “fuel

injector return O-ring”

• Fuel injection unit must be installed in the same cylinder.
• Check the fuel injectors and installation locations for contam‐

ination before assembling.

• The fuel injectors must not have any damage.
• Lubricate all of the O-rings with assembly oil or engine oil be‐

fore installing.

If a Used Fuel Injector Is Installed:
– Spray the tip of the fuel injector with a rust removing spray.

Remove the rust or oil particles with a rag after approximately

five minutes.

– To remove the used copper gasket from the fuel injector,

clamp the gasket carefully in a vise until the clamping jaws on

the vise prevent the copper gasket from turning. Pull the fuel

injector out of the copper gasket by hand with slight rotating

and pulling motions.

– Use a plastic socket to install the copper gasket.

– To avoid damaging the O-ring, slide the new O-ring -2- for the

fuel return connection over the assembly mandrel -1-.

– To remove rust particles on the fuel injector sealing surface,

clean the fuel injector duct in the cylinder head with a cloth

dampened with engine oil or rust remover. Do not damage the

sealing flanges.

3. Diesel Direct Injection System    

317

Sleeve - T10377- .

– Slide the fuel injector cover on.
– Slide the clamping bracket onto the fuel injector and make sure

it is positioned correctly. Refer to

⇒ Fig. ““Tensioning Bracket Installation Position”“ ,

page 314

 .

– Insert the fuel injector in the fuel injector shaft.

Caution

When installing the fuel injector nuts, the nut could fall into the

cylinder head. Work very carefully to avoid unnecessary work

or damage.

– Mount the nuts on the tension bracket by hand and tighten

them. Tightening specification -item 17-

⇒ Item 17 (page 313)

 .

– Turn the cover for the fuel injectors to its installed position and

tighten it. Tightening specification -item 19-

⇒ Item 19 (page 313)

 .

– Install the high pressure lines. Refer to

⇒ “3.4.1 High Pressure Lines, Installing”, page 318

 .

Note

After replacing one or more injectors, the “injector quantity cali‐

bration” and the “injection pressure calibration” for the new injec‐

tors must be must be programmed into the engine control module

using. Refer to Vehicle Diagnostic Tester in Guided Functions.

3.4.1

High Pressure Lines, Installing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-

318

 

 

 

 

 

 

 

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