Fuel Injectors

Two Piece Intake Manifold

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 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. Refer to => [ Lower Intake Manifold, with Fuel Rail ]. Lower Intake Manifold, With Fuel Rail

Cylinder 2, 4 and 6 injectors

- Remove the fuel rail => [ Lower Intake Manifold, with Fuel Rail ]. Lower Intake Manifold, With Fuel Rail

Continuation for All Injectors

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





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

- Install the (T10133/15) into the groove - arrow - on the fuel injector.





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





- Carefully remove the fuel injector.





Installing

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





- Check the plastic support washer - item 10 -=> [ Support Washer ] Two Piece Intake Manifold for damage and replace it if necessary. Refer to => [ Fuel Injector Teflon Seal and Washer ]. Fuel Injector Teflon Seal and Washer

- Replace the spring - 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 13 -=> [ Seal ] Two Piece Intake Manifold must also be replaced at 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.

Cylinder 1, 3 and 5 injectors

- 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 + 90° (1/4) additional turn.

Cylinder 2, 4 and 6 injectors

- Install the fuel rail. Refer to => [ Lower Intake Manifold, with Fuel Rail ]. Lower Intake Manifold, With Fuel Rail

Continuation for All Fuel Injectors

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