Fuel Injectors

Fuel Injectors

Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

• Each time a fuel injector is replaced, the Teflon(R) seal must also be replaced. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.

• The long fuel injectors for cylinders 1, 3 and 5 must not be separated.

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Tool Set (T10133)

Removing

- Remove the lower intake manifold. Refer to => [ Lower Intake Manifold with Fuel Rail ] Lower Intake Manifold with Fuel Rail.

- If the fuel injectors for cylinders 1, 3 and 5 are to be removed, remove the fuel rail.

- Push the O-ring upward by hand as shown and remove it from fuel injector.






- Install the hammer (T10133/3) to the puller (T10133/15).

- Then guide the puller (T10133/15) onto the groove - arrow - on the fuel injector.






• The spring - arrow - must not be removed before removing the fuel injectors.






- Carefully remove the fuel injector.






Installing

- Thoroughly clean the injector bores in the cylinder head using the nylon brush (T10133/4).






- Check the plastic support washer - item 17 - in the => [ Fuel Rail with High Pressure Pump and Injectors Overview ] Fuel Rail with High Pressure Pump and Injectors Overview, for damage and replace it if necessary. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.

- Replace the spring - arrow - and the Teflon(R) seal each time a fuel injector is removed. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.






- Replace the O-rings between the fuel injectors and fuel rail and coat them lightly with clean motor oil.

• The seal - item 22 - in the => [ Fuel Rail with High Pressure Pump and Injectors Overview ] Fuel Rail with High Pressure Pump and Injectors Overview, must also be replaced for fuel injectors for cylinders 1, 3 and 5.

• The Teflon(R) seal on the fuel injector may not be oiled or greased.

- Press the fuel injector by hand into the cylinder head bore until it stops.

- Check the fuel injectors for correct seating and installed position in the cylinder head.

If the fuel injectors for cylinders 1, 3 and 5 were removed:

- Place the fuel rail on and press it evenly onto the fuel injectors.

- Tighten the fuel rail with new bolts uniformly. Tightening specification: 30 Nm + an additional 90° (1/4) turn.

- Install the lower intake manifold. Refer to => [ Lower Intake Manifold with Fuel Rail ] Lower Intake Manifold with Fuel Rail.