Removing The Injector Valve (Injector)

WARNING: This page is about a different variant/trim than selected.

WARNING: Highly inflammable or explosive materials

Danger of Are or explosion
1. → Avoid contact with hot parts or sources of ignition.
2. → Use suction to remove ignitable vapours.
3. → Attach warning sign in a clearly visible position.
4. → Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
5. → Secure collection containers/vessels to prevent them from tipping over.

NOTIFICATION

Dirt on injection system components

Material damage
Rough-running engine
Bad exhaust emissions
1. → Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
2. → Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
3. → Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
4. → Only install clean parts. Do not take spare parts out of the packaging until just before installation.
5. → Never use compressed air when the system is open. Do not move the vehicle.

Information

The removal and installation of the injector valves is described using tools from the > T10133C - tool kit :
Puller T10133/2A
Impact hammer T10133/3
Assembly cone T10133/5
Assembly sleeve T10133/6
Calibrating sleeve T10133/7+8
Calibration sleeve > T90011 - tool kit (HDEV5)
Assembly pin T10133/9
Sleeve T10133/18A
Puller > T10498 - Disassembly Tool
M8 screw T10133/21
Brush > T90006 - Cleaning Tool
Teflon sealing ring

Information

The steps required for removal are shown on one side. The steps required for removal are identical on both sides.

Screw > T40012 - adapter-1- with compressed air adapter -2- into the spark plug bore and tightened by hand.

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Adapter in spark plug bore for compressed-air connection

Information
- Always comply with the procedure described here.
- Set compressed air supply to maximum 1 bar.
Set compressed air supply to max. 1 bar and connect compressed air hose -2- to adapter -1- .

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Compressed-air connection on adapter, in spark plug thread
Keep turning the crankshaft using the vibration damper until the valves on the relevant cylinder are closed.
You will hear a distinct change in the noise!
Remove sealing ring -1- or the injector -2- at the top using a plastic wedge -3- .

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Sealing ring on injector, top
Cover the injector opening at the top with adhesive tape to prevent dirt from escaping.
Information
- Compressed air will escape through the bore on the injector valve when pulling off the injector valve.
- This will blow out any dirt particles. Wear protective goggles!
  Extraction tools for injectors:
- V6 2.9 l engines: > T10133/19 - Puller
- V6 3.0 l engines: > T10133C - Tool set /10
- V8 engines: > T90005 - Puller
Only required if injector valve remains stuck in the cylinder head:
Remove injector valve -1- from the cylinder head.

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Injector valve
1. 6.1 Using > V.A.G 1783 - torque wrench 2-10 Nm , set a torque of 5 Nm.
2. 6.2 Insert puller -2- into the groove on the injector valve -1- .
3. 6.3 Fit puller -3- .
4. 6.4 Loosen M8 screw -4- to the prescribed torque. > Torque 5 Nm (3.7 ftlb.)
Only required if the injector valve cannot be released:
Loosen injector valve -1- using sleeve -2- .

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Loosening injector valve using sleeve
1. 7.1 Remove extraction tool.
2. 7.2 Push sleeve -2- over the injector valve -1- .
3. 7.3 Using a hammer -3- , carefully tap several times on the sleeve -2- .
Carefully clean the injector slot on the cylinder head.
> 244029 CLEAN INJECTOR SLOT
Clean injector valves, that will be re-used, in the ultrasonic cleaning bath and dry them.