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Installing the high pressure lines > < Checking the injection units in open state

Octavia Mk2

Removing and installing the injection units
Removing and installing the injection units
Special tools and workshop equipment required
t  Extractor -T10055-
t  Assembly sleeve -T10377-
t  Extractor -T10415-
Removing
  Note
t  Safety precautions when working on the fuel supply system → Chapter.
t  Observe rules for cleanliness → Chapter.
–  Remove engine cover → Chapter.
  Caution
t  Mark the assignment of the injection units to the cylinders. They must only be re-used on the same cylinder.
t  Immediately close the open connections with suitable caps.
   
–  Detach the return-flow line connections at the injection units. To do so, press down the clamps -1- and -2- and at the same time pull up the unlocking bolt -arrow-.
  A23-10455
–  Disconnect the plug -arrows- at the injection units.
  Caution
When slackening the union nuts for the high pressure lines, counterhold the connection fitting with a lateral wrench. If the connection fitting loosens, this can cause leakage.
–  Unscrew the union nuts of the relevant high pressure line -1, 2, 3- or -4- and remove the corresponding high pressure line.
  A23-10456
–  Release the screw -1- of the clamping claw for the injection unit to be removed.
–  Position the extractor -T10055- with the extractor -T10415- and pull out the injection unit towards the top by tapping it.
  Note
t  In order not to damage the sealing lip of the gasket ring in the cylinder head cover, pull out the injection unit with rotary movements.
t  Place the removed injection units on a clean cloth.
Important instructions for the replacement of parts
When reinstalling the injection unit, the following parts must be replaced:
t  Copper seal
t  O-ring for gasket of bore in cylinder head
t  O-ring for fuel return-flow line
t  Screw for clamping claw
When installing the new injection unit, the following must also be replaced:
t  Clamping claw
t  High pressure line of cylinder
Instructions for reinstalling the injection units
  Note
t  When reinstalling, the removed injection units, the high pressure lines and the clamping claws must only be installed again at the same point.
t  The reinstalled injection units or high pressure lines must not be damaged.
–  Spray the tip of the injection unit with a rust solvent spray. Remove the soot and grease particles with a cloth after approx. 5 minutes.
–  Remove the old copper seal from the injection unit; to do so, carefully tighten the copper seal in a vice until the copper seal does no longer turn. Then pull the injection unit out of the copper seal with slight turning and pulling movements of the hand.
l  Check the injection units and the fitting positions for cleanliness before installing.
Mounting sequence
  Note
t  All the O-rings must be coated with engine oil before installing.
t  Carefully check all the parts and the fitting positions for cleanliness before installing.
–  Remove the soot particles on the sealing surface of the injection unit in the cylinder head and the dirt in the opening with a cloth soaked in engine oil or in rust solvent, if necessary.
  Caution
Make sure the sealing surfaces are not damaged in the process.
–  Insert a new copper seal on the injection unit with plastic bushing.
  A23-10458
–  Replace the O-ring for the gasket of the bore for the injection unit head, to do so use the assembly sleeve -T10377-.
–  Carefully slide the new and oiled O-ring onto the fuel return-flow connection.
  Caution
Pay particular attention in order to avoid unnecessary installation work or consequential damage.
Avoid damage and contact of the injection units with the cylinder head.
–  Always insert 2 injection units with clamping claw carefully into the holes of the cylinder head, while doing so observe the fitting position.
–  Screw in the new fixing screw of the clamping claw and only slightly tighten to a tightening torque of maximum 1 - 2 Nm.
  Note
In order to install the high pressure line free of stress, it must be possible to align the injection unit by turning it slightly.
–  Install the high pressure line free of tension, to do so, align the position of the injection unit by turning it slightly. Only tighten the union nuts by hand.
–  Tighten the fixing screw of the clamping claw. Tightening torque and tightening order → Chapter.
–  Tighten the union nuts of the high pressure lines. Tightening torque and tightening order → Chapter.
–  Carefully press the connection of the fuel return-flow line via the gasket ring onto the injection unit.
l  The cap must click audibly into place.
–  Afterwards carefully press the securing bolt downwards.
  Note
After replacing one or several injection units, carry out the adaptation according to their codes „injector quantity adjustment IQA“ and „injector voltage adjustment IVA“ → Vehicle diagnostic tester.
  Note
The return-flow lines must only be replaced complete with the pressure holding valve → Electronic Catalogue of Original Parts.
–  Check fuel system for tightness → Chapter.
  N23-10246

Installing the high pressure lines > < Checking the injection units in open state