Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ Ring spanner 3035

Note:

Defective injectors cause the following faults:

• ◆ Misfiring
• ◆ Knocking in one or more cylinders
• ◆ Engine over-heating
• ◆ Loss of power
• ◆ Excessive black exhaust smoke
• ◆ Higher fuel consumption
• ◆ Excessive blue smoke when starting from cold

Defective injectors can be located by loosening the high pressure pipe union on each injector in turn with the engine running at a fast idling speed. If engine speed remains constant after loosening a pipe union, this indicates a defective injector.

Removing

• ‒ Remove injection pipes with an slotted ring spanner 3035.

Note:

Always remove pipe set complete. Do not alter pipe shape.

• ‒ Remove securing nut, take off retainer and take out injector.

Installing

Note:

Always renew heat insulating seal between cylinder head and injectors.

• ‒ Insert injector.
• ‒ Check mounting is seated correctly in cylinder head.
• ‒ Fit retainer.

Tightening torques:
     Injection pipes = 25 Nm
     Retainer screw = 20 Nm