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Volkswagen Workshop Service and Repair Manuals

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Removing and installing high-pressure accumulator (rail) > < Removing

Polo Mk5

Installing
Installing
Important instructions for working on fuel system → Chapter
Fitting used injectors
l  Ensure that the injector bore is clean before fitting.
When a used injector is re-fitted, the following must be replaced:
t  Copper seal
t  O-ring for injector shaft
t  Retaining clip for injector return
Also use if necessary.
t  O-ring for return line
t  Injector seal
–  Spray tip of injector with rust-releasing spray. Wait approx. 5 minutes and wipe off soot particles and oil 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.
  Note
It must be ensured that the brass brush does not touch the holes in the injection nozzles.
   
–  To remove the old copper seal from the injector, carefully clamp the copper seal in a pair of pliers so it is just prevented from spinning.
–  Then carefully pull and twist the injector out of the copper seal by hand.
–  Clean off deposits under the copper seal using a suitable scraper.
  Caution
Risk of damage to sealing surface for injector.
To remove carbon deposits from the injector sealing surface, clean the injector shaft in the cylinder head with a cloth soaked in engine oil or rust solvent.
  N23-10296
–  Fit renewed clips before fitting the injector. To do this, grease lightly.
Fitting new injectors:
When a fitting a new injector, the following must be replaced:
Included in scope of supply.
t  Copper seal
t  O-ring for injector shaft
t  O-ring for injector return line
t  Retaining clip for injector return
Also use if necessary.
t  Injector seal
Continuation for used and new injectors:
–  Use a plastic socket to mount new copper seal.
–  Lubricate all O-rings with engine oil or assembly oil before installing.
–  Fit new O-rings for injector shaft.
–  Push clamping piece onto injectors, during this process pay attention to installation position.
–  Carefully guide two injectors at a time into the injector bores in the cylinder head.
–  Tighten bolt for clamp to a maximum of only 1 - 2 Nm at first → Item.
l  Injectors must still be able to move.
–  Install high-pressure lines → Chapter.
Further assembly in reverse order of removal.
–  Tighten injectors → Chapter
–  Adapt correction values for injectors → Chapter.
  N15-10445

Removing and installing high-pressure accumulator (rail) > < Removing