With Plastic Intake Manifold
Fuel Injector
Special tools, testers and auxiliary items required
• Torque wrench (VAG 1331)
• SW 17 socket (VAG 1331/6)
• SW 14 socket, open ring (VAG 1331/8)
• Tool set (T10133)
Removing
• The following describes removing and installing and the left injectors (cylinder bank 2).
CAUTION!
• Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to => [ Releasing Pressure on High Pressure Side ] Service and Repair.
• Then wrap a clean cloth around the connection and relieve residual pressure by carefully loosening the connection.
- Remove intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Disconnect the connectors - arrows - and the vacuum hose - 1 -.
- Remove the high pressure lines - 1 and 2 -. To do this, counter hold at hex head with and open end wrench and loosen the union nut.
- Remove the bolts - arrows -.
• Do not change the angles of the high pressure lines.
- Remove fuel rail with fuel injectors.
If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows:
- Using a screwdriver, bend the retaining tabs - 1 - of the radial adjustment aside - arrow - and pull the support ring - 2 - from the fuel injector.
- Remove O-ring from fuel injector.
- Attach slide wrench (T10133/3) with adapter (T10133/10).
- Guide puller (T10133/10) into groove on fuel injector and carefully drive fuel injector out in - direction of arrow -.
• When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.
- Carefully remove the old combustion chamber seal - arrow -, thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.
- Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.
Installing
• Replace combustion chamber seal and O-ring.
• Replace spacer ring if damaged.
• Lightly moisten fuel injector O-rings with clean engine oil.
• Reinsert injectors at same cylinder.
- Clean bore in cylinder head with nylon cylinder brush (T10133/4).
- Clip the radial adjustment - 1 - to the support ring - 2 -.
- When reinstalling a fuel injector, use a clean cloth to clean combustion residue from the groove for combustion chamber seal and the shaft of the fuel injector.
- Place assembly cone (T10133/5) with new combustion chamber seal - 1 - on fuel injector - 2 -.
- Slide combustion chamber seal as far possible onto assembly cone (T10133/5) using assembly sleeve (T10133/6).
- Turn assembly sleeve (T10133/6) around and slide combustion chamber seal into groove.
• When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.
- Press the sizing sleeve (T10133/7) with a slight turning motion (approximately 180 degrees) onto the fuel injector until it stops.
- Pull the sizing sleeve (T10133/7) off again, turning it in the opposite direction.
- Press the sizing sleeve (T10133/8) with a slight turning motion (approximately 180 degrees) onto the fuel injector until it stops.
- Pull the sizing sleeve (T10133/8) off again, turning it in the opposite direction.
- Lubricate the new O-ring with clean engine oil before installing.
• The combustion chamber seal must not be lubricated.
- Slide fuel injector into the bore cylinder head as far as stop using assembly drift (T10133/9).
• The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.
- Make sure fuel injectors are correctly positioned in cylinder head.
• The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.
- Press the fuel rail onto the fuel injectors with uniform pressure.
- Fasten bolts - arrows - in a diagonal sequence and in several steps. Tightening specifications => [ (Item 12) Bolt ] Description and Operation.
• High pressure line connections must not show any signs of damage.
• Do not change the angles of the high pressure lines.
- Hand-tighten the union nuts for the high-pressure lines.
- Make sure the high-pressure lines are seated free of stress.
- To tighten SW 14 union nut on high pressure line, use torque wrench (VAG 1331) with socket insert AF 14, open ring (VAG 1331/8).
- To tighten SW 17 union nut for high pressure line, use the torque wrench (VAG 1331) with SW 17 socket (VAG 1331/6).
- Only install retaining tabs after high pressure lines have been tightened.
Further installation is performed in reverse order of removal, noting the following:
- Install intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Fill with coolant if necessary. Refer to => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
Tightening Specifications
