Part 2. Replacing rings on VAG 1.2/1.4/1.9/2.0/2.5/5.0TDI, 2.0SDI unit injectors
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Part 1. Video about disassembly and installation of the pump-injector: • Ch. 1. VAG: Dismantling installation pump-force... Video on the important nuances of replacing the mounting sealing rings on pump-injectors (or PD, from the German Pumpe-Düse) engine group VAG 1.2/1.4/1.9/2.0/2.5/5.0TDI, 2.0SDI with letter codes: 1.2 TDI (3-cylinder) ANY, AYZ 1.4 TDI (3-cylinder) AMF, BMS, BNM, BNV 1.9 TDI (4-cylinder) AJM, ANU, ASZ, ATD, AUY, AVB, AVF , AXB, AXC, AXR, BJB, BKC, BKE, BLS, BRR, BRS, BRU, BSU, BSW, BTB, BVK, BXE, BXF, BXJ 2.0 TDI (4-cylinder) BGW, BHW, BMM, BMP, BPW , BRT, BVH 2.0 SDI (4-cylinder) BDJ, BDK, BST 2.5 TDI (5-cylinder) AXD, AXE, BAC, BLJ, BLK, BNZ, BPC, BPD, BPE 5.0 TDI (10-cylinder) AYH, BLE each of which was installed on specific models: Lupo (6X1), Polo (6N2/9N1), Golf 4 (1J1/1J5)/Golf 5(1K1/1K5), Bora (1J2/1J6), Jetta (1K2), Passat ( 3B2/3B3/3B5/3B6/B5), Sharan (7M9/7M6)/Ford Galaxy ('00), Touran (1T1/1T2), Touareg (7LA/7L6), Caddy (2K), Transporter T5 (7H), Audi A3 (8L1/8P1)/A4 (B5/B6/B7)/A6 (C5), Škoda Fabia (6Y3/6Y5/5J2/5J5), Roomster (5J7), Octavia (1U2/1U5/1Z3/1Z5), Seat Arosa (6H1), Ibiza (6L1/6J1/6J5), Cordoba (6L2), Leon (1M1/1P1), Toledo (1M2/5P2), Alhambra (7V9) from 1998 to 2010. All works with fuel wiring under conditions of maximum cleanliness and accuracy, exclude any ingress of dust and dirt into the work zone, drop or damage to the injection system elements. Or in the video, it was mentioned a little: the electromagnetic valve at the moment of injection blocks the supply, and the return of the fuel, thereby ensuring the creation of pressure on the injector needle, its rise and the implementation of the injected portion of fuel in the current mode of operation of the engine. Well, of course, the location of the hole provides a cone angle of 150°, and the diameter. Repair kit for pump-injector mounting gaskets Bosch for VAG 1.2/1.4/1.9/2.0/2.5/5.0TDI, 2.0SDI with press stud fastening on one bolt each: VAG-original 038 198 051 C FORD 1 144 500 Bosch 1 417 010 997 Elring 900.650 Reinz 15-38642-03 Febi 40135 Pump-injector clamping bolt (disposable!) M6X64, must be replaced with a new one at each installation VAG-original 038 103 385 A FORD 1 100 599 Tightening torque: step 1: 12 Nm step 2: 270° Bolt axis pump-injector M8X90 VAG-original 038 103 714 A tightening torque (starting from the two middle bolts on each axle with the pressure screws on the pump-injector loosened): step 1: 20 Nm step 2: 90° Screw pressure arm M12X1,25X26,75 VAG-original WHT 000 530 separate post-cylinder adjustment MUST! In the maximum upper position, the camshaft is pushed onto the roller, i.e. with full compression of the pump-injector throttle: step 1: hand-tighten without any twists and excessive force step 2: reverse opening to 180° and fixing with a torque of 30 Nm.
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