TENSIONING Bracket Installation Position

Fig 1: Identifying Tensioning Plate Installed Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

If a Used Fuel Injector is Installed:

-- Spray the tip of the fuel injector with a rust removing spray. Remove the rust or oil particles with a rag after approximately 5 minutes.

-- If an injector is very dirty, clean the tips around the copper sealing ring with a soft brush. Do not let the brush come in contact with the holes for the jets.

-- To remove the used copper sealing ring from the fuel injector, clamp the sealing ring carefully in a vise until the clamping jaws on the vise prevent the ring from turning. Pull the fuel injector out of the copper sealing ring by hand with slight twisting and pulling motions.

-- Use a scraper to remove any deposits under the copper sealing ring.

-- Use a plastic socket to install the copper ring.

-- Check the O-ring for the fuel return line connection at the injector for damage and deformation.

Is There Identifiable O-Ring Damage or Deformation:

-- Replace O-ring for fuel return line connection. O-rings must be moist when installed.

-- Coat the fuel return connection O-ring and the fuel return connection with assembly oil or clean engine oil.

-- Carefully roll the new O-ring onto the fuel return connection. Check for correct seating.

Continuation

-- To remove rust particles on the fuel injector sealing surface, clean the fuel injector duct in the cylinder head with a cloth dampened with engine oil or rust remover. Do not damage the sealing flanges.

-- Install the fuel injectors.

-- First tighten the union nuts on the high pressure or injection lines by hand.

-- Make sure the lines are seated correctly without tension.

-- Tighten the high pressure lines:

14 mm. Refer to Fig 2

Fig 2: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 14 mm 3150

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17 mm. Refer to Fig 3

Fig 3: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 Mm T40055

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19 mm. Refer to Fig 4

Fig 4: Identifying High Pressure Line To Fuel Rail And 19 mm Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the return line connections carefully over the sealing ring onto the injector (check the sealing ring first for damage). The connection must engage audibly. Then press the release pin down carefully.

-- Check and adjusts the injector correction values. Refer to INJECTOR CORRECTION VALUES, CHECK AND ADJUST .

-- Bleed the fuel system and then check for leaks. Refer to FUEL SYSTEM, BLEEDING AND FIRST TIME FILLING .

If there are leaks even though the correct tightening specification was used, replace the affected component.

Follow all safety precautions during the road test. Refer to SAFETY PRECAUTIONS .

-- Test drive the vehicle a minimum of 20 km/h and using full throttle at least one time. Then check the high pressure area one more time for leaks.