Volkswagen Workshop Service and Repair Manuals

Removing and installing injectors Note safety precautions before beginning work → Chapter.   Note Teflon seal on injector must be renewed each time after removing injector → Chapter. Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Tool set -T10133- Removing –  Remove intake manifold → Chapter. –  Remove lower part of intake manifold → Chapter.

–  Press the O-ring upwards by hand as shown, and remove it from the injector. –  Screw slide hammer -T10133/3- to puller -T10133/15-.

–  Then insert puller -T10133/15- into groove -arrow- on injector.

–  Pull injector out by tapping carefully. Installing

–  Thoroughly clean injector holes in cylinder head using nylon brush -T10133/4-. –  Check plastic support washer for damage, renew if necessary → Chapter.

–  Renew spring element -arrow- and Teflon seal each time the injectors are removed → Chapter. –  Renew O-rings between injector and lower part of intake manifold and moisten slightly with clean engine oil.   Note The Teflon seal on the injector must not be oiled or greased. –  Push injector into cylinder head bore to stop by hand.   Note The injector must insert easily. If necessary wait until the seal has contracted sufficiently. –  Ensure correct position of injectors in cylinder head. –  Place lower part of intake manifold carefully on injectors and tighten securing bolts to 20 Nm → Chapter. –  Install intake manifold → Chapter.