Fuel Injectors: Installing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Replacing the following components and seal or O-ring after removing

Tension Clamp
Copper washer
O-ring from the fuel injector shaft
O-ring from the fuel injector return

Replacing the following components and seal or O-ring after removing a fuel injector

Tension Clamp
Fuel injection line
Copper washer
O-ring from the fuel injector shaft
O-ring from the fuel injector return

Fuel injection unit must be installed in the same cylinder.
Make sure the fuel injectors and their installation locations are clean before installing.
The fuel injectors must not have any damage.
Coat all the O-rings with installation oil or assembly oil before installing.

If a used fuel injector is being re-installed

-- 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 sealing ring from the fuel injector, clamp the sealing ring carefully in a vise until the clamping jaws on the vise prevent the ring from turning. Pull the fuel injector out of the copper sealing ring by hand with slight twisting and pulling motions.

-- Install the new copper ring using a plastic bushing.

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

Fig 1: Identifying Seal At Particles To Assembly Drift

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Clean the fuel injector duct in the cylinder head with a cloth dampened with engine oil or rust remover to remove rust particles on the fuel injector sealing surface. Do not damage the sealing flanges.

-- Replace the fuel injector shaft seal using the Guide SleeveT10377.

Fig 2: Identifying Guide Sleeve T10377 To Replace Fuel Injector Shaft Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the fuel injector cover.

-- Push the tension bracket onto the fuel injector. Make sure it is installed correctly Figure.

-- Install the fuel injector into the fuel injector shaft.

CAUTION: When installing the fuel injector nuts, the nut could fall into the cylinder head. Work very carefully to avoid unnecessary work or damage.

-- Position the tensioning bracket nuts carefully and tighten them by hand. Tightening specification -item 17-.

-- Turn the fuel injector cover into the installation position and tighten it. Tightening specification -item 19-.

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

NOTE: The "injector quantity calibration" and the "injector pressure calibration" for the new fuel injectors must be programmed in the engine control module after replacing one or more fuel injectors.