Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 712

The fuel rail will continue to be filled with fuel, but it will no longer

be under high pressure.

CAUTION

Fuel system is under pressure.
Risk of injury from fuel spraying out.
– Wear protective eyewear.
– Wear safety gloves.
– Reduce the pressure: Lay clean cloths around the connec‐

tion location and carefully open the connection point.

– After reducing fuel high pressure, place a clean cloth around

the connection and open the high pressure system »immedi‐

ately«. Collect any draining fuel.

Note

♦

If the high pressure system is not opened immediately, the

pressure will increase because of post-heating.

♦

The ignition can no longer be switched on, otherwise the pres‐

sure will increase again.

2

Fuel Injectors

⇒ “2.1 Overview - Fuel Injector”, page 285
⇒ “2.2 Fuel Injectors, Removing and Installing”, page 285
⇒ “2.4 Fuel Injector Seals, Replacing”, page 288
⇒ “2.5 Fuel Injectors, Cleaning”, page 291

2.1

Overview - Fuel Injector

1 - Replace intermediate ring
2 - Replace the mount
3 - Combustion chamber sealing ring (Teflon

®

 sealing ring), re‐

place, the ring must not be greased or handled with any other

lubricants when installing.
4 - Fuel Injector
5 - Replace the spacer ring
6 - Replace the O-ring (lightly coat with clean engine oil during

installation)
7 - Replace the support ring (via this support ring, fuel rail utilizes

the force to hold the fuel injector in place in the cylinder head).

2.2

Fuel Injectors, Removing and Installing

Special tools and workshop equipment required
♦ Injector/Combustion Chamber Seal Tool Set - T10133C-
♦ Injector/Combustion Chamber Seal Tool Set - 18 - T10133/18-
♦ Puller - T10133/2A-
♦ Removal Tool Injector/Combustion Chamber Seal Tool Set -

16A - T10133/16A-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Mount - Fuel Injector
♦ O-ring - Fuel Injector
♦ Ring - Intermediate Fuel Injector
♦ Ring - Sealing Combustion Chamber
♦ Ring - Spacer
♦ Ring - Support
Removing

Note

The fuel injectors can only be removed when the engine is cold.

– Remove the intake manifold. Refer to

⇒ “4.3 Intake Manifold, Removing and Installing”, page 304

 .

– Remove the fuel rail. Refer to

⇒ “4.4 Fuel Rail, Removing and Installing, Direct Fuel Injec‐

tion”, page 309

 .

Removing Fuel Injectors, in the Event That They Are Stuck in the

Fuel Rail
Carefully remove the fuel injectors out of the fuel rail.
Removing Fuel Injectors, in the Event That They Are Stuck in the

Cylinder Head
– Cover the open intake channels with a clean cloth.
– Remove the electrical connector on the fuel injector that is

about to be removed.

– Push the Injector/Combustion Chamber Seal Tool Set - 18 -

T10133/18- over the fuel injector.

– Carefully hit the sleeve to loosen the fuel injector.

– Guide the Puller - T10133/2A- in the groove on the fuel injec‐

tor.

– Install the Removal Tool Injector/Combustion Chamber Seal

Tool Set - 16A - T10133/16A- .

– Remove the fuel injector by using the torque wrench -1- to turn

the bolt.

– If the tightening specification limit of »5 Nm« is achieved with‐

out the fuel injector loosening, remove the puller and loosen

the fuel injector with the sleeve.

Note

♦

The fuel injectors may be damaged if the tightening specifica‐

tions are not observed.

♦

The combustion chamber seal must always be replaced be‐

fore installing the fuel injector. Refer to

⇒ “2.4 Fuel Injector Seals, Replacing”, page 288

 .

– Replace combustion chamber seal and install fuel injector.

Refer to 

⇒ “2.4 Fuel Injector Seals, Replacing”, page 288

 .

2.3

Intake Manifold-Fuel Injectors, Remov‐

ing and Installing

Note

Vehicles with the engine codes CNTA do not have an intake

manifold-fuel injector.

Removing
– Remove the fuel return hose -1- from the intake manifold.
– Disconnect the connectors -3- from the mount.
– Disconnect the connectors -4 and 5-.
– Free up the wiring harness -1- from the fuel rail.