Fuel Injectors: Installing

Installing New Fuel Injectors 

The following must be replaced when installing a new fuel injection:

• Copper Ring
• O-ring for the fuel injector shaft
• O-ring for the fuel return line 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 Ring
• O-ring for the fuel injector shaft
• O-ring for the fuel return line 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 sealing ring from the fuel injector, clamp the sealing ring carefully in a vise.

-- Clamp the copper ring 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.

-- Clean any deposits from under the copper ring.

-- Replace the seal for the fuel injector, to do this use the O-ring Assembly Sleeve T10377.

Fig 1: Identifying Guide Sleeve T10377 To Replace Fuel Injector Shaft Seal

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 injector.

-- First tighten the high pressure lines union nuts by hand. 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 .

• Tightening specification, refer to OVERVIEW - FUEL INJECTORS .