VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing injectors

Special tools and workshop equipment required
   
Tool set for FSI engines -T10133 C- with -T10133/16 A- and -T10133/19-
Removing
Risk of functional impairment due to soiling → Chapter.
  Note
Injectors must only be removed when the engine is cold.
–  Remove intake manifold → Chapter.
 

Removing and installing injectors

–  Removing fuel rail → Chapter.
–  Remove O-ring -3- from injector -1-.
–  Unplug electrical connector from corresponding injector.
 

Removing and installing injectors

–  Lever support ring -1- off injector using a screwdriver -2-.
 

Removing and installing injectors

–  Fit impact sleeve -T10133/18- over injector.
 

Removing and installing injectors

–  Carefully loosen injector with light blows onto impact sleeve.
  Note
Use a torque wrench to pull out the injector.
Set the torque wrench to 5 Nm.
 

Removing and installing injectors

–  Fit puller -T10133/19- to groove on injector.
–  Fit removing tool -T10133/16 A- to puller.
–  Pull out injector by screwing in bolt -1-.
–  If the torque limit of »5 Nm« has been reached and the injector still can't be pulled out, remove the puller and use the impact sleeve again to loosen the injector.
–  Repeat the procedure on each injector.
  Note
If the torque limit is exceeded, the injector may become damaged.
The combustion chamber ring seal must always be renewed prior to reinstalling the injector.
–  Remove gasket for lower part of intake manifold.
 

Removing and installing injectors

Dismantling injector:
–  Pull support ring -4- and spacer ring -2- off injector -1-.
–  Remove circlip -7-, upper sealing washer -5- and lower sealing washer -6-.
–  Carefully remove old combustion chamber seal -8-. To do this, cut the ring open using a knife or spread the ring using a screwdriver and pull it off towards front.
  Note
Take care not to damage the groove of injector. The injector must be renewed if the groove is damaged.
 

Removing and installing injectors

Installing
–  Clean hole in cylinder head using nylon brush -T10133/4-.
  Note
Renew combustion chamber seal and O-ring.
Renew spacer ring if damaged.
–  When reinstalling the injector, remove any combustion residue from groove for combustion chamber ring seal and from injector shaft using a clean cloth.
 

Removing and installing injectors

–  Fit assembly cone -T10133/5- with a new combustion chamber ring seal -1- on injector -2-.
 

Removing and installing injectors

–  Slide combustion chamber ring seal with assembly sleeve -T10133/6- onto assembly cone -T10133/5- as far as it will go.
 

Removing and installing injectors

–  Turn assembly sleeve -T10133/6- around and push combustion chamber ring seal into the respective groove.
  Note
 

Removing and installing injectors

The combustion chamber ring seal is widened when it is pushed onto the injector. It must be compressed again after sliding on and this is done in two stages as described below.
–  Push calibration sleeve -T10133/7- onto injector as far as stop and simultaneously turn it slightly (approx. 180°).
–  Pull calibration sleeve -T10133/7- off again, turning in opposite direction.
 

Removing and installing injectors

–  Push calibration sleeve -T10133/8- onto injector as far as stop and simultaneously turn it slightly (approx. 180°).
–  Pull calibration sleeve -T10133/8- off again, turning in opposite direction.
–  Fit support ring -4- and spacer ring -2- onto injector -1-.
 

Removing and installing injectors

–  Before installing injector -1- moisten new O-ring -3- with clean engine oil.
  Note
The combustion chamber ring seal -8- must not be lubricated.
–  Push injectors by hand as far as stop into the hole of the cylinder head (free of oil and grease). Ensure injectors are positioned correctly in cylinder head.
  Note
The injectors must insert easily. If necessary, wait until the combustion chamber ring seal has contracted sufficiently.
Ensure injectors are correctly seated and positioned in cylinder head.
Electrical connector of injector must engage in respective recess in cylinder head.
–  Installing fuel rail → Chapter.
–  Install intake manifold → Chapter.
–  Connect vehicle diagnostic tester and carry out guided function “Clear adaption values for injectors”.
–  Switch off ignition.
 

Removing and installing injectors

Removing and installing fuel rail
Removing The fuel system is under high pressure.Risk of injury due to fuel which may spurt out.Release high pressure. → Chapter ...

Cleaning injectors
Special tools and workshop equipment required Ultrasonic cleaner -VAS 6418- Mounting plate for injection modules - ...

Other materials:

Overview of fitting locations - front keyless entry system, LHD vehicles
1 -  Front passenger door exterior handle With front passenger door exterior handle contact sensor -G416-. Removing and installing → Chapter With front passenger side aerial for entry and start system -R135-. Removing ...

Technical data
General repair instructions Repairing electrical wiring harnesses and connectors → Electrical System, General Information; Rep. gr.97 Releasing and dismantling connector housings → Electrical Sys ...

Overview of fitting locations - entry and start authorisation system, RHD vehicles
1 -  Immobiliser reader coil -D2- Removing and installing → Chapter 2 -  Control unit for electronic steering column lock -J764- Removing and installing → Running gear, axles, steering ...

© 2016-2019 Copyright www.vwgolf.org