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Pelican Technical Article:

Replacing Your Fuel Injectors

Steve Vernon

Time:

3 hours3 hrs

Tab:

$20 to $450

Talent:

***

Tools:

Injector Replacement tool kit, rags

Applicable Models:

VW GTI (2006-09)

Parts Required:

New injectors, injector seal kit

Hot Tip:

Check for flooded cylinders

Performance Gain:

Better-running engine, improved fuel mileage

Complementary Modification:

Replace worn out hoses

If your car is starting to run rough, getting horrible gas mileage or has an injector error code, there is a good chance it is time to replace the fuel injectors. On a direct port injection motor a properly working injector will send a precise amount of atomized fuel into the combustion chamber at a designated time. A weak or improperly working injector can do everything from send no fuel, to leak raw, non-atomized fuel into your engine.

If you are going to be replacing your injectors, the first step is to prep the car. I like to tell people to pull out the fuse for the fuel pump and then try to start the car. The car will turn over and then die. Do this about 2-3 times - it will help drain excess fuel out of your system, also open the gas cap to help depressurize the system. Then, make sure that the car has cooled down; you don't want to be working with gasoline when the car is hot.

Have a fire extinguisher handy, there will be some spillage of fuel as it's nearly impossible to prevent. Also, wear chemical resistant gloves if you don't want to get any gasoline on your hands, and make sure that you have plenty of paper towels or rags to help you clean up. Perform the injector removal in a clear, open, and well-ventilated space, and it may not hurt to have an assistant around in case there are any problems.

You are going to be opening holes that go into the engine so before you begin get a can of compressed air and blow all the dust and debris away from the injector ports.

You will need to remove the intake manifold on the GTI MkV to get to the injectors. Please see our article on intake manifold removal for further assistance and perform that work before beginning this project.

This article will show you how to remove, replace the seals and reinstall the injectors. If you purchase new injectors they come with new seals but you can use this article for the removal and installation procedure. The injectors are not cheap and are subject to damage if you do not use the proper tools. While we have heard of people removing and installing injectors without using the proper Volkswagen tools without issue, this article will show you the proper tools and usage.

When removing the manifold some times the injectors will come out with the manifold (red arrows).
Figure 1

When removing the manifold some times the injectors will come out with the manifold (red arrows). This is not uncommon but most of the time the injector seals to the fuel rail are the weakest point and the injectors will stay in the engine. Remove the manifold carefully in case some injectors stay in the head and some come out with the manifold. If you aren't careful you can damage the wiring.

This is what the engine will look like after you have removed the intake manifold and the injectors (red arrows) are still in the head.
Figure 2

This is what the engine will look like after you have removed the intake manifold and the injectors (red arrows) are still in the head.

If the injectors are in the head there is a very good chance the seal is in the fuel rail (yellow arrow).
Figure 3

If the injectors are in the head there is a very good chance the seal is in the fuel rail (yellow arrow). Make sure you remove the old seal before attempting to reinstall the fuel rail.

The injector seal kit comes with a new Teflon combustion camber seal (red arrow), injector to fuel rail seal (yellow arrow), support disk (green arrow), radial compensator (blue arrow) and support ring (purple arrow).
Figure 4

The injector seal kit comes with a new Teflon combustion camber seal (red arrow), injector to fuel rail seal (yellow arrow), support disk (green arrow), radial compensator (blue arrow) and support ring (purple arrow).

Begin by disconnecting the wiring harness from the injectors (red arrow, one shown).
Figure 5

Begin by disconnecting the wiring harness from the injectors (red arrow, one shown).

Stuff some clean rags in the intake ports to protect them from anything getting into the head (red arrows).
Figure 6

Stuff some clean rags in the intake ports to protect them from anything getting into the head (red arrows). There are two small retaining tabs on the radial compensators for each injector (green arrows, upper tabs shown, lower tabs hidden) If you have older style they will be made of plastic and the newer ones are made of metal. Bend them back away from the injectors. This will destroy the compensators and they will need to be replaced.

With the tabs bent out of the way you can remove the supporting clips (red arrow).
Figure 7

With the tabs bent out of the way you can remove the supporting clips (red arrow).

Install the guide puller into the grooves on the injector (red arrow) and use the slide puller (yellow arrow) to gently tap the injector out.
Figure 8

Install the guide puller into the grooves on the injector (red arrow) and use the slide puller (yellow arrow) to gently tap the injector out. This is where using the proper tool is important. The injectors clearance tolerances on the port are very small and if you are pulling the injector by hand you run the risk of damaging the head or destroying the injector.

With the injector out you can see the Teflon chamber seal (red arrow), the support disk (yellow arrow) and the injector to fuel rail seal (blue arrow).
Figure 9

With the injector out you can see the Teflon chamber seal (red arrow), the support disk (yellow arrow) and the injector to fuel rail seal (blue arrow). The combustion chamber Teflon seal and fuel rail seal must be replaced every time.

Carefully remove the Teflon chamber seal while not doing any damage to the injector or ridge in the channel the Teflon seal will sit in (red arrow).
Figure 10

Carefully remove the Teflon chamber seal while not doing any damage to the injector or ridge in the channel the Teflon seal will sit in (red arrow). You will slide the new seal (yellow arrow) over the tapered installation tool (green arrow) by hand and then down onto the injector. The adjusting ring will be used later (purple arrow)

Slide the new Teflon combustion chamber seal down over the installation tool by hand (red arrow).
Figure 11

Slide the new Teflon combustion chamber seal down over the installation tool by hand (red arrow). Do NOT use any lubricants as this will destroy the seal.

Position the tool at the end of the injector and slide the seal into the groove (red arrow).
Figure 12

Position the tool at the end of the injector and slide the seal into the groove (red arrow). Note how the seal is loose in the channel and needs to be calibrated.

Slide the calibration tool with the beveled outer side down over the seal (red arrow).
Figure 13

Slide the calibration tool with the beveled outer side down over the seal (red arrow). Turn the adjusting ring using moderate force 180 degrees in one direction and then 180 degrees back to the original position.

The support ring does not need to be replaced unless damaged.
Figure 14

The support ring does not need to be replaced unless damaged. The ring has a slit in it (red arrow) When installing the new ring do NOT stretch it, install it like a screw over the collar. The flat non stepped side must face the O-ring.

Here is an injector with the new Teflon combustion chamber seal (red arrow), radial compensator (blue arrow), support ring (green arrow), support disk (yellow arrow) and fuel rail seal (purple arrow) installed and the injector is now ready for installation back into the head.
Figure 15

Here is an injector with the new Teflon combustion chamber seal (red arrow), radial compensator (blue arrow), support ring (green arrow), support disk (yellow arrow) and fuel rail seal (purple arrow) installed and the injector is now ready for installation back into the head.

Clean the injector port with a Nylon brush (red arrow).
Figure 16

Clean the injector port with a Nylon brush (red arrow). Note: the intake valve may interfere with the Nylon brush necessitating turning the valve train for clearance. If you have not disconnected the timing belt you will be fine but if you have removed the belt and turn the motor or valve train make sure to line everything back up again. Please see our article on timing belt replacement for details.

Use the injector installation tool and push the injector straight in.
Figure 17

Use the injector installation tool and push the injector straight in. People have wrapped the injectors in towels and tapped them in but again this opens up the possibility of damaging the injector or head. Use the right tool for the job (red arrow).

This photo illustrates a newly sealed injector (red arrow) next to an injector in need of seals (yellow arrow).
Figure 18

This photo illustrates a newly sealed injector (red arrow) next to an injector in need of seals (yellow arrow). Note the angle of the new injector. There is a cut out in the head to clear the wiring connection, make sure you take note of that when installing the injector. The injector will not seat correctly if the cut out for the harness connection is not lined up. Perform the seal injector replacement for the other injectors and then follow the instructions for reattaching the intake manifold. Put a little clean motor oil on the fuel rail O-ring before installation.

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Comments and Suggestions:
Sieza82 Comments: Hi Guys i am driving Golf 5 GTI it started jerking/staddering when changing gears, I am not sure if its anything related to injectors or intake velves
April 29, 2016
  Followup from the Pelican Staff: Is the check engine light on? Sounds like an engine misfire. I would check spark, fuel and compression on all cylinders.
- Nick at Pelican Parts
 
Jdawg Comments: Where can I find just the radial compensator ring
April 21, 2016
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
arnet1990 Comments: Where do we get the adjusting ring tool shown in picture 10,11, and 13?

Thanks
January 14, 2016
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799. They can get it for you.
- Nick at Pelican Parts
 

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Page last updated: Wed 12/7/2016 02:41:52 AM