Volkswagen Workshop Service and Repair Manuals

Renewing Teflon seal and support washer on injector Special tools and workshop equipment required

t  Tool set -T10133- Procedure Renewing Teflon seal Remove air filter → Chapter. Remove regulating flap control unit -J808- and throttle valve module -J338- → Chapter. –  Remove intake manifold and lower part of intake manifold → Chapter.   Note Before removing, lock vacuum actuator using a 2.5 mm drill bit. –  Remove injectors → Chapter. –  Clean injector carefully. –  Carefully cut open seal with a knife as shown -arrow-. Avoid contact between knife blade and valve body under all circumstances.

–  Remove old seal and clean seal groove in area of seal -arrow-. Remove coking deposits using a brass wire brush.

–  Fit new oil seal -1- onto assembly cone -T10133/5-. Using assembly sleeve -T10133/6- (knurling points to seal -1-), gently slide seal onto assembly cone -T10133/5- as far as possible.

–  Turn assembly sleeve -T10133/6- around (knurling no longer points to seal) and push seal -1- to end of assembly cone -T10133/5-. –  Now place assembly cone -T10133/5- with seal onto injector from front. Slide seal further onto injector using assembly sleeve -T10133/6-.

The seal is not yet seated in its groove. –  Remove assembly sleeve -T10133/6- and assembly cone -T10133/5-. –  Slide seal into annular groove by hand. –  Position spacer sleeve -T10133/11- onto valve body. –  Now push calibration sleeve -T10133/7- over seal to stop onto spacer sleeve -T10133/11-.

–  Pull off calibration sleeve -T10133/7- again. –  Now push calibration sleeve -T10133/8- over seal to stop onto spacer sleeve -T10133/11-. –  Pull off calibration sleeve -T10133/8- again.

Now the Teflon seal has correct installation dimensions. Renewing support washer

–  Remove O-ring -3-. –  Cut support washer -2- open with a small pair of side cutters and remove it. –  Pull spring element -1- off injector and replace with retaining plate -T10133/12-.

–  Place new support washer -1- onto assembly cone -T10133/13- and position onto injector as shown. –  Slide support washer -1- into first groove -arrow- on injector using calibration sleeve -T10133/17- (knurled side points to injector).

–  Now turn calibration sleeve -T10133/17- around (knurled side no longer points to injector). Slide calibration sleeve over support washer -1- in direction of -arrow- to stop on retaining plate -T10133/12-. –  Pull calibration sleeve -T10133/17- down again. The support washer now has correct installation dimensions.

–  Now position a new spring element -1- for retaining plate -T10133/12- and position a new O-ring -3- in front of support washer -2-.   Note

The Teflon seal -arrow- must not be oiled to install injector. –  Install injectors → Chapter. –  Place lower part of intake manifold carefully on injectors and tighten securing bolts to 20 Nm → Chapter.   Note t  Before installation, lock vacuum actuator using a 2.5 mm drill bit. t  After installation of lower part of intake manifold, remove 2.5 mm drill bit. –  Install intake manifold → Chapter. –  Install regulating flap control unit -J808- and throttle valve module -J338- → Chapter. Install air filter → Chapter. Further installation is carried out in the reverse sequence of removal.