Fuel Injectors

Fuel Injectors

• Do not disassemble the high pressure pump!

• If a fuel injector is removed, then the combustion chamber Teflon(R) seal and the support washer must always be replaced => [ Combustion Chamber Teflon(R) Seal and Support Washer ] Combustion Chamber Teflon(R) Seal and Support Washer.

• Read the safety precautions before starting. Refer to => [ Fuel System ] Fuel System.

• Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

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.

Cylinders 1, 3 and 5 Fuel 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.

Cylinders 2, 4 and 6 Fuel Injectors

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

Continuation for All

- Push the O-ring upward as illustrated and remove it from the fuel injector.






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

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






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






- Remove the fuel injector by carefully tapping.






Installing






- Clean the fuel injector bores in the cylinder head thoroughly using the nylon brush (T10133/4).

- Check the plastic support washer for damage and replace if necessary. Refer to => [ Combustion Chamber Teflon(R) Seal and Support Washer ] Combustion Chamber Teflon(R) Seal and Support Washer.

- Replace the spring - arrow - and the combustion chamber Teflon(R) seal each time the fuel injector is removed. Refer to => [ Combustion Chamber Teflon(R) Seal and Support Washer ] Combustion Chamber Teflon(R) Seal and Support Washer.






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

• The seal (- item 4 - in the => [ Fuel Injector Overview, Cylinders 1, 3 and 5 ] Fuel Injector Overview, Cylinders 1, 3 and 5) must also be replaced on fuel injectors for cylinders 1, 3 and 5.

• Do not oil or grease the combustion chamber Teflon(R) seal on the fuel injector.

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

- Make sure the fuel injectors are installed securely in the cylinder head.

Cylinder 1, 3 and 5 Fuel Injectors

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

- Install the fuel rail with new bolts and tighten them evenly. Tightening specification: 30 Nm + an additional 90° (1/4) turn.

Cylinder 2, 4 and 6 Fuel Injectors

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

Continuation for All

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