Injectors, removing and installing

Only vehicles with engine code ALH

Recommended special tools and equipment

V.A.G1331 torque wrench (5 to 50 Nm)
3035 Injector line wrench

NOTE: Malfunctioning injectors cause the following malfunctions:

Rough engine idle
Diesel knock
Knocking in one or more cylinders
Engine overheating
Loss of power
Excessive black smoke
High fuel consumption
Excessive black smoke during cold start

Malfunctioning injectors can be located by loosening the injector line union nuts on each injector in turn, with the engine running at a fast idling speed. If the engine speed remains constant after loosening an injector line union nut, this indicates a malfunctioning injector.

Removing

Remove injectors lines using 3035 injector line wrench.

NOTE: Always remove wiring set completely. Do not change bend shape.

Loosen securing bolt, remove tension bracket and injector.
Cover openings with a clean rag.

Installing

NOTE: Always replace the heat protection seal between cylinder head and injectors.

Insert injectors.
Be sure mounting brackets are properly seated in cylinder head.
Insert tension bracket.

Tightening torques:

Injector lines = 25 Nm

Tension bracket bolt = 20 Nm

Erase DTC memory of control module for Diesel-Direct fuel injection system. Refer to Diagnostic mode 4: Reset/erase diagnostic data .
Generate readiness code.