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 seal must also be replaced. Refer to => [ Fuel Injector Teflon Seal and Washer ] Fuel Injector Teflon 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 (T10133/3) to the (T10133/15).

- Guide the (T10133/15) onto the groove - arrow - on the fuel injector.





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





- Carefully remove the fuel injector.





Installing

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





- Check the plastic support washer - item 4 -=> [ Support Washer ] Fuel Rail, Injectors and High Pressure Pump Overview for damage and replace it if necessary. Refer to => [ Fuel Injector Teflon Seal and Washer ] Fuel Injector Teflon Seal and Washer.

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





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

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

• The Teflon seal for the fuel injector may not be oiled or greased.

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

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

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

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

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

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