Fuel Injectors

Fuel Injectors

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• 17 mm Socket (V.A.G 1331/6)

• SW 14 socket, Open Ring (V.A.G 1331/8)

• Tool Set (T10133)

Removing

• Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

• Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

- Drain the coolant.

- Remove intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

• Seal injector channels in cylinder heads with clean cloths.

- Disconnect electrical harness connectors at fuel injectors.

- Remove high pressure line - 5 - from connector on fuel rail.





- Remove high pressure line - 7 - from connector on fuel rail. To do this, counterhold at hex head with and open-end wrench and loosen the union nut.

- Remove bolts - 1, 2, 3, 4, 6, 8 -.

• Do not change the angles of the high pressure lines.

- Remove fuel rail with fuel injectors.

If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows:





- Using a screwdriver, bend the retaining tabs - 1 - of the radial adjustment aside - arrow - and pull the support ring - 2 - from the fuel injector.

- Remove O-ring from fuel injector.

- Guide the (T10133/2A) in the groove on the fuel injector.





- Then position the trim removal wedge (T10133/16) and remove the fuel injector by loosening the bolt - 1 -.

• When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.

- Carefully remove the old combustion chamber seal - arrow -, thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.





- Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.

Installing

• Replace combustion chamber seal and O-ring.

• Replace spacer ring if damaged.

• Lightly coat fuel injector O-rings with clean engine oil.

• Re-insert injector lines at same cylinder.

- Clean bore in cylinder head with (T10133/4).





- Clip the radial adjustment - 1 - to the support ring - 2 -.





- When re-installing a fuel injector, use a clean cloth to clean combustion residue from the groove for combustion chamber seal and the shaft of the fuel injector.

- Place (T10133/5) with new combustion chamber seal - 1 - on fuel injector - 2 -.





- Slide combustion chamber seal as far possible onto (T10133/5) using (T10133/6).





- Turn (T10133/6) around and slide combustion chamber seal into groove.

• When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.

- Press the (T10133/7) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.





- Pull the (T10133/7) off again, turning it in the opposite direction.

- Press the (T10133/8) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.





- Pull the (T10133/8) off again, turning it in the opposite direction.

- Coat the new O-ring with clean engine oil before installing.

• The combustion chamber seal must not be oiled.

- Slide fuel injector into the bore cylinder head as far as stop using (T10133/9).





• The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.

- Make sure fuel injectors are correctly positioned in cylinder head.

• The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.

- Press the fuel rail onto the fuel injectors with uniform pressure.

- Tighten bolts - 1, 2, 3, 4, 6, 8 - diagonally in stages.





• Tightening Specifications. Refer to => [ Fuel Injectors and Fuel Rail Assembly Overview ] Removal and Replacement

• High pressure line connections must not show any signs of damage.

• Do not change the angles of the high pressure lines.

- Hand-tighten the union nuts for the high-pressure lines.

- Make sure the high-pressure lines are seated free of stress.

- To tighten SW 14 union nut on high pressure line, use (V.A.G 1331) with (V.A.G 1331/8).





- To tighten SW 17 union nut for high pressure line, use the (V.A.G 1331) with (V.A.G 1331/6).





- Only install retaining tabs after high pressure lines have been tightened.

Further installation is in reverse order of removal, note the following:

- Install intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.