Removing and installing injectors

Note safety precautions before beginning work ⇒ 2.1 Safety regulations for working on fuel supply.

Special tools and workshop equipment required

• Torque wrench - V.A.G 1331-

• Tool set - T10133-

Removing

Remove air filter ⇒ 1.3 Removing and installing air filter housing.

Remove regulating flap control unit - J808- and throttle valve module - J338- ⇒ 2.2 Removing and installing regulating flap control unit - J808- and throttle valve module - J338-.

• Remove intake manifold and lower part of intake manifold ⇒ 2.1 Assembly overview - intake manifold.

• Press O-ring upwards by hand as shown, and remove it from injector.
• Screw slide hammer - T10133/3- to puller - T10133/15-.

• Then insert puller - T10133/15- into groove -arrow- on injector.

• Pull injector out by tapping carefully.

Installing

• Thoroughly clean injector holes in cylinder head using nylon brush - T10133/4-.
• Check plastic support washer for damage, renew if necessary ⇒ 3.3 Renewing seals on injectors.

• Renew spring element -arrow- and Teflon seal each time after removing injectors ⇒ 3.3 Renewing seals on injectors.
• Renew O-rings between injector and lower part of intake manifold and moisten slightly with clean engine oil.

• Push injector into cylinder head bore to stop by hand.

• Ensure correct position of injectors in cylinder head.
• Place lower part of intake manifold carefully on injectors and tighten securing bolts to 20 Nm ⇒ 2.1 Assembly overview - intake manifold.
• Install intake manifold ⇒ 2.1 Assembly overview - intake manifold.
• Install regulating flap control unit - J808- and throttle valve module - J338- ⇒ 2.2 Removing and installing regulating flap control unit - J808- and throttle valve module - J338-.

Install air filter ⇒ 1.3 Removing and installing air filter housing.

• Connect ⇒ Vehicle diagnostic tester and perform Guided Function “Deleting injector adaptation values”.
• Switch off ignition.