Volkswagen Golf Service & Repair Manual: Removing and installing injectors

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Mixture preparation system, electronic inj., Gas / Injectors / 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:

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