Volkswagen Workshop Service and Repair Manuals

Removing and installing injectors Special tools and workshop equipment required

t  Tool set -T10133-   Note Puller -T10133/2- tool has been modified and is now designated puller -T10133/2A-. If the new tool is not yet available in the workshop, perform the modification yourself. Convert puller -T10133/2- tool to puller -T10133/2A- tool. Special tools and workshop equipment required t  Round file approx. 6 mm

–  File out a semi-circular recess as shown in the illustration. The recess allows the tool to be pushed further onto the injector so the contact surface is increased. –  For identification purposes, mark the modified tool with the letter „A“ after the tool number.

Injector (old version) 1 -  Combustion chamber ring seal (Teflon ring seal) - renew; when fitting, do not grease ring or use any other lubricant 2 -  The support ring must be replaced with an intermediate ring. See Injector (new version) 3 -  Injector 4 -  Spacer ring (renew if damaged) 5 -  O-ring (renew; to install, lightly lubricate with clean engine oil). 6 -  Support ring (via this support ring, the fuel rail exerts force which secures injector in cylinder head)

Injector (new version) 1 -  Replace intermediate ring 2 -  Mounting 3 -  Combustion chamber ring seal (Teflon ring seal) - renew; when fitting, do not grease ring or use any other lubricant 4 -  Injector 5 -  Spacer ring (renew if damaged) 6 -  O-ring (renew; to install, lightly lubricate with clean engine oil). 7 -  Support ring (via this support ring, fuel rail exerts force which secures injector in cylinder head) Removing: –  Removing intake manifold with fuel rail → Chapter.   Note If the injectors remain in the fuel rail, pull them out of the fuel rail. –  Seal intake ports with a clean cloth.

–  Remove supporting element -A- and pull off connectors -arrows- from injectors.

–  Apply puller -T10133/2A- to groove on injector. –  Position removal tool -T10133/16- and pull injector out by turning bolt -1-.   Note t  Note the intermediate rings. t  The Teflon seal must always be renewed prior to reinstallation of the injector → Chapter. 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 of high-pressure injectors in cylinder head using a nylon brush -T10133/4-. –  Renew Teflon seal of injector → Chapter. –  Complete injector with parts from the repair set.

–  Push injector by hand as far as it will go into the hole of the cylinder head (free of oil and grease). Ensure injectors are positioned correctly -arrow- in cylinder head.   Note

If it is not possible to insert the injector by hand, use the puller -T10133/2A--2- with a hammer -T10133/3- to insert the injector. –  Fit support ring onto injector. –  Lightly moisten O-rings of the high-pressure injector with clean engine oil. –  Installing intake manifold with fuel rail → Chapter.