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Newly seal injection pump > < Dynamically testing and setting the commencement of injection

Octavia Mk1

Removing and installing, testing the injection nozzles
Removing and installing, testing the injection nozzles
  Note
t  Defective injection nozzles cause the following malfunctions:
t  Reduced performance
t  Excessively black exhaust smoke
t  Increased blue smoke during cold start
t  Increased fuel consumption
t  Engine overheats
t  Knocking on one or more cylinders
t  Misfiring
Special tools and workshop equipment required
t  Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3-
t  Injection nozzle tester (e. g. -V.A.G 1322 -)
t  Pressure line -V.A.G 1322/2-
t  Ring spanner for injection lines (e.g. -3035 -)
t  if necessary extractor for valve-stem joint -MP1-230 (3364)- and auxiliary tool
Removing
–  Remove injection lines using the ring spanner (e.g. -3035 -).
–  If necessary release hollow screw for return-flow line (injection nozzle 3).
  Note
Always remove injection lines completely. Do not change bending change.
–  Release fixing screw, remove clamp and remove injection nozzle.
For jammed nozzles prepare the following auxiliary tool:
Preparing an auxiliary tool
–  Saw off an injection line (e.g. spare part line) approx. 5 cm behind the nozzle union nut.
–  Hard solder an M6 bolt to the sawn off line.
–  Thoroughly clean the auxiliary tool, the injection nozzle cannot be used if dirty!
   
–  Tighten the union nut of the auxiliary tool on the jammed nozzle and insert the extractor -MP1-230- on the welded nut.
  Note
Store the auxiliary tool with dust protection for future use.
Install
  Note
Always replace the copper joint between the cylinder head and the injection nozzles.
–  Replace the injection nozzles.
–  Pay attention to the correct position of the brackets in the cylinder head.
–  Insert clamp and tighten fixing screw.
Tightening torques:
t  Injection lines: 25 Nm
t  Hollow screw for return-flow line (cyl. 3): 10 Nm
t  Screw for clamp: 20 Nm
Test
–  Connect vehicle system tester -V.A.G 1552- and activate the function “read measured value block” → Chapter.
  S23-0029
–  Read measured value block, display group 013, engine at idling speed → Chapter.
Specified value: -1.50 mg/s... +1.50 mg/s (Milligram per stroke)
–  If one or more nominal values are outside the tolerance, interchange the injection nozzles with each other (except for the nozzle of cylinder 3).
–  If the fault migrates with the nozzle, replace the injection nozzle.
–  If the fault remains on the cylinder, check the compression.
–  If the compression is O.K., replace the relevant pressure valve with gasket ring → Chapter.
  Note
t  The gasket ring must be removed from the pump with a soft object (plastic, wood) as otherwise the contact surfaces may be scratched.
t  For mileages above 15.000 km replace the pressure valves per set only.
This engine is fitted with 2 spring injection nozzles. This is why the injection of the fuel quantity occurs in 2 steps. If there is a problem with these injection nozzles they must be replaced, as neither a pressure adjustment nor a repair is possible.
  
Reading measured value block 13     ->
0.82mg/s   -0.12mg/s   0.49mg/s
–  Test injection nozzles with injection nozzle tester (e.g. -V.A.G 1322-) and pressure line -V.A.G 1322/2 -).
  WARNING
When testing injection nozzles make sure the fuel jet does not touch your hands as fuel under high pressure penetrates the skin and may cause severe injuries.
l  Pressure gauge connected
–  Slowly press down the pump lever. During commencement of spray read off the spray pressure. If the injection pressure deviates from the nominal value, replace the injection nozzles.
  V02-0184
New nozzles19...20 MPa
Wear limit17 MPa

Check tightness
l  Pressure gauge connected
–  Press the pump lever slowly down and maintain pressure for 10 seconds at 15 MPa. No fuel may trickle from the nozzle opening.
–  If there is a leak replace injection nozzle.
   

Newly seal injection pump > < Dynamically testing and setting the commencement of injection