Removing and installing injectors

Special tools and workshop equipment required

• Puller - T10055-
• Assembly sleeve - T10377-
• Socket - T40055-
• Torque wrench - V.A.G 1331-
• Ratchet wrench - V.A.G 1331/1-
• Support sleeve - T10411-

• Injector remover - T10426-

3.4.1 Removing

»Carry out the following work sequence«

• Remove engine cover panel ⇒ 3 Engine cover panel.

• Pull charge pressure positioner connector -1- off turbocharger.
• Remove breather line between cylinder head cover -2- and intake hose. Press plug-in connectors together to do this.

Protect open fuel connections from dirt entrainment using suitable methods under all circumstances.

• Open return line connection. Release catch -1- to do this.
• Pull fuel return line connection off injector in direction of arrow.

• Pull connector -1- off at the injectors to be removed.

Renew connector seal of connector -1- ⇒ Item 5 (page 194) ⇒ ETKA (Electronic Parts Catalogue).

• Detach high-pressure line -2- between fuel rail and high-pressure pump.
• Removing high-pressure lines between fuel rail and injectors.

• Unscrew securing bolt of clamping piece for injector to be removed.

• Position puller - T10055- with injector puller - T10426- as shown.
• Using tapping movements, always pull injectors out upwards together with clamping piece.

3.4.2 Installing

Important instructions for installing injectors

• Clean empty injector bores and sealing surfaces in cylinder head using cleaning set - VAS 6811- before fitting injectors ⇒ Instructions
• When removing and installing, always renew the following components and seals/O-rings: “bolt for clamping piece”, “copper seal”, “O-ring for injector bore”.
• Used injectors may only be re-installed on the same cylinder.
• High-pressure lines may only be re-installed on the same cylinder.
• Check injectors and installation area for cleanliness before installing.
• The injectors must be completely undamaged.
• Lubricate all O-rings with engine oil or assembly oil before installing.

If a used injector is being re-installed:

• Spray tip of injector with a rust removal spray. Wait approx. 5 minutes, then wipe off soot and oil particles with a cloth.

• To remove the old copper seal from the injector, carefully clamp the copper seal in a pair of pliers so the copper seal is just prevented from spinning. Then carefully pull and twist the injector out of the copper seal by hand.
• Use a plastic socket to mount the new copper seal.

Use a cloth soaked in engine oil or rust remover to remove soot particles on sealing surface of injectors and sealing surface in cylinder head.

• Clean injector bore using a cloth soaked in engine oil or rust remover. Do not damage sealing surface.

• Renew seal for injector bore using assembly sleeve - T10377-.

• Ensure that the injector bore is clean before fitting.

• Push the clamping piece onto the injector.
• Carefully insert injectors together with the clamping piece into injector bores in cylinder head.

Avoid damage to the injectors and prevent them coming into contact with the cylinder head.

• Initially tighten securing bolts only to 1 - 2 Nm.

It should be possible to align the injectors while fitting the highpressure lines by hand.

• Install high-pressure lines ⇒ 3.4.2 Installing.
• Tightening injectors ⇒ Item 9 (page 194)

Further assembly in reverse order of removal.

After renewing one or more injectors:

• Write adapted correction values for new injectors into engine control unit ⇒ 3.1 Assembly overview - injectors.
• Reset learnt values of fuel pressure regulating valve - N276-.
• 01 - Engine electronics
• 01 - Engine electronics functions
• 01 - Reset adaptation values of engine ctrl. module