Fuel Injector

Special tools and workshop equipment required 

• Puller T10055 with adapter T10055/1
• Guide Sleeve T10377
• Socket T40055
• Torque Wrench (5-50 Nm) V.A.G 1331
• Ratchet, Reversible V.A.G 1331/1

Removing 

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the protective strip -item 1- in the FUEL RAIL AND INJECTORS OVERVIEW , if equipped.

-- Disconnect the connector -1- from the fuel injector to be removed.

Fig 1: Identifying Fuel Injector Connectors -1-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Before removing, dry the return line connection on the fuel injector that will be removed (for example using a commercially available detergent).

-- Dry the return line connection.

-- Cover the return line connection with a cloth.

-- Remove the fuel return line connection from the fuel injector that is going to be removed. Pull it upward to release it.

Fig 2: Identifying Removal Of Fuel Return Line Connection From Fuel Injector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the high pressure line between the fuel rail and fuel injector that will be removed.

-- Remove the bolts for the sealing cap on the fuel injector that will be removed.

-- Raise the sealing cap slightly and rotate it 90° to access the fuel injector nuts.

-- Remove the nuts on the corresponding fuel injector.

-- Position the puller T10055 with the adapter T10055/1 as illustrated and remove the fuel injector upward using a slight knocking motion.

Fig 3: Identifying Puller T10055 With Adapter T10055/1 Positioned To Remove Fuel Injector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing 

Important information on installing the fuel injectors:

• The following components must be replaced each time a fuel injector is removed and installed: "tensioning bracket", "copper washer", "fuel injector shaft seal" and the "fuel injector return seal".
• The following components must be replaced each time an injector is replaced: "tensioning bracket" "fuel injector line" "copper washer" "fuel injector shaft seal" and "fuel injector return seal".
• The fuel injector must be installed in the same cylinder.
• Check the fuel injectors and installation locations for contamination before assembling.
• The fuel injectors must not have any damage.
• Lubricate all of the seals with assembly oil or engine oil before installing.

If a used fuel injector is installed:

-- Spray the tip of the fuel injector with a rust removing spray. Remove the rust or oil particles with a cloth after approximately 5 minutes.

-- To remove the used copper washer from the fuel injector, clamp the washer carefully in a vise until the clamping jaws on the vise prevent the washer from turning. Pull the fuel injector out of the copper washer by hand with a slight twisting and pulling motion.

-- Use a plastic socket to install the copper washer.

-- To avoid damaging the seal, slide the new seal -2- for the fuel return line connection over the assembly drift -1-.

Fig 4: Identifying Seal At particles To Assembly Drift

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To remove rust particles on the fuel injector sealing surface, clean the fuel injector hole in the cylinder head with a cloth dampened with engine oil or rust remover. Do not damage the sealing flanges.

-- Replace the fuel injector shaft seal using the guide sleeve T10377.

Fig 5: Identifying Guide Sleeve T10377 To Replace Fuel Injector Shaft Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the sealing cap on.

-- Slide the tensioning plate onto the fuel injector and make sure it is positioned correctly. Refer to Figure.

-- insert the fuel injector in the fuel injector shaft.

-- Install the nuts for the tensioning plate by hand and then tighten them to specification. Refer to -item 17- in the FUEL RAIL AND INJECTORS OVERVIEW .

-- Turn the sealing cap for the fuel injectors to its installed position and tighten it. Tightening specification, refer to -item 19- in the FUEL RAIL AND INJECTORS OVERVIEW .

-- Install the high pressure lines. Refer to HIGH PRESSURE LINE, INSTALLING .