Volkswagen Workshop Service and Repair Manuals

Removing and installing injectors Special tools and workshop equipment required

t  Tool set for FSI engines -T10133-

Assembly overview - injector 1 -  Radial compensation element (renew) 2 -  Combustion chamber seal (Teflon seal), renew. When installed, ring must not be greased or treated with any other lubricant. 3 -  Groove in injector 4 -  Support washer (renew) 5 -  O-ring (renew; to install, lightly lubricate with clean engine oil.) 6 -  Support ring Removing: –  Remove intake manifold → Chapter. –  Remove fuel rail with intake manifold flaps → Chapter. –  Seal intake ports with a clean cloth.

–  Use a screwdriver to bend retaining lugs of radial compensation element to side, and pull support ring off injector.   Note The retaining lugs of radial compensation element are destroyed by this action (retaining lugs break). The radial compensation element must be renewed when injector is refitted.

–  Screw slide hammer -T10133/3- to puller -T10133/2-. Then guide puller -T10133/2- into groove in injector and carefully hammer injector out. Installing:   Note t  The Teflon seal on the injector must not be oiled or greased. t  It is possible that an open inlet valve hinders cleaning. In this case, turn engine by hand using spanner.

–  Thoroughly clean holes in cylinder head for high-pressure injectors using nylon brush -T10133/4-. –  Renew O-ring and Teflon seal for injector → Chapter.

–  Insert injector in hole in cylinder head to stop using drift -T10133/9-.

–  Ensure correct position of injectors in cylinder head. –  Remove fuel rail with intake manifold flaps → Chapter. –  Install intake manifold → Chapter.