Volkswagen Golf Quiz
Diesel Engine Fuel System

Injector replacement

In this manual: Diesel Engine Fuel System
General Information — 9Engine — 14Engine Disassembly and Assembly, 1.1 and 1.3 l Engines — 15Engine Disassembly and Assembly, 1.6 and 1.8 L Engines — 13Diesel Engine Disassembly and Assembly — 16Fuel System — 1Carburetor Engine Fuel System — 19Fuel injection system — 17Diesel Engine Fuel System — 15Clutch — 12Transmission — 37Transmission — 8Front-wheel drive — 5Steering — 12Front Suspension — 9Rear Suspension — 4Brake System — 16Body — 26Electrical System — 42Wiring Diagrams — 24
~1min read
03060901201507052N·mlb·ft
Tightening torque found on this page

PROCEDURE

A faulty injector can be identified by loosening the fuel line union nuts on the injectors one at a time while the engine runs at idle. If engine speed does not drop when a nut is loosened, that injector is faulty. At service stations, the injector can be checked with a pressure gauge. Main signs of injector failure: – engine misfiring; – knocking in one or more cylinders; – engine overheating; – loss of engine power; – black smoke from the exhaust pipe; – high fuel consumption. PROCEDURE 1. Wash the fuel lines with a cleaning agent and cold water. 2. Loosen and remove the fuel line union nuts. Do not bend or change the shape of the fuel lines. 3. Unscrew the injectors using a 27 mm open-end wrench.

4. Replace the sealing washers between the injector and the cylinder head. Install the washers as shown in the figure; the arrow must point toward the cylinder head. 5. Install the new injectors and tighten them to a torque of 70 N·m. 6. Install the fuel lines and tighten the union nuts to a torque of 25 N·m.

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