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 coolant hose from guide on pressure pipe. –  Unscrew bolts -1- and remove retaining clip.

–  Pull connector -2- off charge air pressure sender -G31- with intake air temperature sender 2 -G299-. –  Unlock catches in -direction of arrow- and pull pressure pipe -3- first off throttle valve module -J338- and then off turbocharger. –  Remove high-pressure pump → Chapter.

–  Remove bolts -arrows- and pull fuel rail off injectors.

–  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. –  Install new O-rings for injectors and coat lightly 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.