Volkswagen Workshop Service and Repair Manuals

Removing and installing injectors Special tools and workshop equipment required

t  Tool set -T10133-

Injector components 1 -  Radial compensation element (renew) 2 -  Combustion chamber ring seal (Teflon ring seal) - renew; when fitting, do not grease ring or use 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. –  Seal intake ports with a clean cloth.

–  Use a screwdriver to bend retaining hooks of radial compensation element to side, and pull support ring off injector.   Note The retaining hooks of radial compensation element are damaged by this action (retaining hooks bend or break). The radial compensation element must be renewed before 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 at crankshaft using a spanner.

–  Thoroughly clean holes of high-pressure injectors in cylinder head using a nylon brush -T10133/4-. –  Renew O-ring, radial compensation element, support washer and Teflon seal of injector → Chapter.

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

–  Ensure correct position of injectors in cylinder head.