Fuel Injectors, Removing And Installing: Installing

Installing New Fuel Injectors 

The Following Must Be Replaced When Installing A New Fuel Injection: 

• Copper Gasket
• O-ring for the fuel injector shaft
• O-ring for the fuel return hose connection

-- Read and follow all instructions on installing the high pressure lines. Refer to HIGH PRESSURE LINE, INSTALLING .

Installing Used Fuel Injectors 

The Following Must Be Replaced When Installing A Used Fuel Injector: 

• Copper Gasket
• O-ring for the fuel injector shaft
• O-ring for the fuel return hose connection

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

-- To remove the used copper gasket from the fuel injector, clamp the gasket carefully in a vise.

-- Clamp the copper gasket in a vise until the clamping jaws on the vise prevent the ring from turning.

-- Pull the fuel injector out of the copper gasket by hand with slight rotating and pulling motions.

-- Remove any deposits from under the copper gasket.

-- Replace the seal for the fuel injector, to do this use the :T10377  .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation For Used And New Fuel Injectors: 

-- Coat the fuel injector O-rings with assembly oil, engine oil, or diesel fuel.

-- Install the fuel injectors.

-- First tighten the high pressure lines union nuts hand-tight. Make sure it fits free-of-tension.

-- The correction values for the new injectors must be must be programmed into the engine control module after replacing one or more injectors. Refer to FUEL INJECTORS, ADAPTING CORRECTION VALUES .

-- Fill/bleed the fuel system. Refer to FUEL SYSTEM, FILLING/BLEEDING .

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