Fuel Injectors Overview

Fig 1: Identifying Fuel Rail And Injectors Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Protective Strip
   • for the rail element (high pressure reservoir). See -item  7- and -item  5-
2. Fuel Return Lines
   • With pressure retaining valve. See -item  8-
   • The fuel return line must be routed correctly. They may be replaced only with the pressure retaining valve.
   • Run the engine at idle for approximately two minutes after replacing to bleed the fuel system and then check the fuel return lines for leaks.
   • Pressure Retention Valve in Fuel Return Line, Checking. Refer to PRESSURE RETAINING VALVE IN FUEL RETURN LINE, CHECKING .
3. Bolt
   • 8 Nm
4. Fuel Return Line
   • Blue or with blue marking
   • Make sure it is secure
   • From the fuel filter
5. High-Pressure Lines
   CAUTION: The high pressure lines can be reused only after the following checks:

   • Check the sealing cone on each high pressure line for deformation and cracks.
   • The bores for the lines must not be deformed, narrowed or damaged.
   • Do not use corroded lines again.
   • Between the rail element (high pressure reservoir). See -item  7- and -item  20-
   • Do not interchange
   • When installing, the fuel injectors. See -item  20- and high pressure lines may only be installed on the same cylinder as before.
   • Do not change the angles of the high pressure lines
   • Install without tension
   • 28 Nm
6. Fuel Pressure Regulator Valve -N276-
   • Removing and installing. Refer to FUEL PRESSURE REGULATOR VALVE -N276- .
   • 80 Nm
7. Rail Element (High Pressure Reservoir)
8. Fuel Temperature Sensor -G81-
9. Fuel Supply Line
   • Make sure it is secure
   • Between the Fuel Temperature Sensor -G81-. See -item  8- and -item  10-
10. Fuel High Pressure Pump
    • With Fuel Metering Valve -N290- item  1-
    • Removing and installing. Refer to HIGH PRESSURE FUEL PUMP .
    • The fuel system "must" always be filled after replacing (never run dry) (refer to FUEL SYSTEM, FILLING/BLEEDING ), Fuel System, Filling.
11. Bolt
    • Tightening specification. Refer to HIGH PRESSURE PUMP OVERVIEW .
12. Bracket
    • For the fuel temperature sensor -G81- -item 8-
13. Fuel Supply Line
    • White or with white markings
    • Make sure it is secure
    • From the Auxiliary Fuel Pump -V393-
    • Auxiliary Fuel Pump -V393- removing and installing. Refer to REMOVAL AND INSTALLATION .
14. Fuel Pressure Sensor -G247-
    • Removing and installing. Refer to FUEL PRESSURE SENSOR -G247- .
    • 100 Nm
15. Bolt
    • 22 Nm
16. Tension Clamp
    • Installation position Fig 2.
    • Replace after removing
17. Nut
    • 10 Nm
18. Injection Unit Cover
19. Bolt
    • 5 Nm
20. Fuel Injector (Injector)
    • The following components and seals and/or O-ring must be replaced at every removal and installation: "tension bracket", "copper washer", "fuel injection unit shaft O-ring" and "fuel injection return O-ring".
    • The following components and seals and/or O-ring must be replaced when replacing the fuel injection unit: "tensioning claw", "fuel injection line", "copper washer" "fuel injection unit shaft O-ring" "fuel injection unit return O-ring"
    • When installing, the fuel injectors -item  20- and high pressure lines may only be installed on the same cylinder as before.
    • Removing and installing. Refer to FUEL INJECTORS .
21. High Pressure Line
    • between the high pressure fuel pump -item  10- and rail element (high pressure reservoir) -item  7-
      CAUTION: The high pressure lines can be reused only after the following checks:

      • Check the sealing cone on each high pressure line for deformation and cracks.
      • The bores for the lines must not be deformed, narrowed or damaged.
      • Do not use corroded lines again.
    • Do not change the angles of the high pressure line.
    • Install without tension
    • 28 Nm

Fig 2: Identifying Tensioning Plate Installed Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 3: Identifying Fuel Return Line Differences

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-A-, no ribbing: for connecting the overflow oil line, use a clamp.

-B-, with ribbing: for connecting the overflow oil line, do NOT use a clamp