Fuel Injectors

Fuel Injectors

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

• Each time a fuel injector is replaced, the Teflon 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 upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

Cylinder 1, 3 and 5 Injectors

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

- Remove the fuel rail.

Cylinder 2, 4 and 6 Injectors

- Remove the fuel rail.

Continuation for All

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






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

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






• The spring - arrow - must not be removed prior to removing the injectors.






- Remove the fuel injector carefully.






Installing

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






- Check the washer - item 10 - in the => [ Fuel Rail, Injectors and High Pressure Pump Overview ] Fuel Rail, Injectors and High Pressure Pump 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 Teflon(R) seal each time the 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 engine oil.

• The seal (- item 13 - in the => [ Fuel Rail, Injectors and High Pressure Pump Overview ] Fuel Rail, Injectors and High Pressure Pump Overview) must also be replaced on the fuel injectors for cylinders 1, 3 and 5.

• The Teflon(R) seal must not be oiled or greased.

- Press the fuel injector by hand, into the cylinder head bore until it is seated.

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

Cylinder 1, 3 and 5 Injectors

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

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

Cylinder 2, 4 and 6 Injectors

- Install the fuel rail.

Continuation for All

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