Injector seals location

Discussion in 'VW Mk6 Golf, Jetta, Beetle, Sportwagen TDI forum' started by Slammedtdi, Dec 21, 2017.

  1. Slammedtdi

    Slammedtdi New Member

    Dec 16, 2017
    2010 Sportwagen Tdi
    Charleston SC
    hey guys. finishing the rebuild of my entire fuel system and HPFP on my 2010 sportwagen. Starting to put the injectors back in but can’t figure out where the deal goes on the exterior of the Bosch injector. There is 3 locations it could be but can’t find any diagrams online. Has anybody done this before?
    Last edited by a moderator: Dec 21, 2017
  2. mdrake

    mdrake New Member

    Dec 19, 2010
    2010 Golf TDI 6-spd 2-door
    Southern California
    This must be related to your other post questions about removing the HPFP. I offer you up the steps out of the factory repair manual about installing injectors. Curious why you didn't take pictures or noted locations as everything came apart.

    I attached the picture of the page that refers to a special tool for seal installation. Sorry no detailed view of seal location.

    Take some pictures to include on these threads! I'm also interested if you plan to do any of the injector quantity and pressure calibration or any VCDS work if you are replacing injectors.

    Important Information When Installing the Fuel Injectors:
    • Using the Cleaning Set - VAS6811- , clean the empty fuel injector
    shafts and sealing surfaces in the cylinder head before
    installing the injectors. Refer to the Owner's Manual
    • The following components, seals or O-rings must be replaced
    during each removal and installation, or when a fuel injector is
    being replaced: “Tensioning plate”, “copper washer”, “fuel injector
    shaft O-ring” “fuel injector return O-ring”
    • If the fuel injector is being reused, then it must be installed in
    the same cylinder from which it was removed.
    • Check the fuel injectors and installed locations for contamination
    before assembling.
    • The fuel injectors must not have any damage.
    • Lubricate all of the O-rings with assembly oil or engine oil before
    If a Used Fuel Injector Is Reinstalled Again:
    – Spray the tip of the fuel injector with a rust removing spray.
    Remove the rust or oil particles with a cloth after approximately
    5 minutes.
    – To remove the used copper washer from the fuel injector,
    clamp the washer carefully in a vise until the vise jaws prevent
    the washer from turning. Pull the fuel injector out of the washer
    by hand with a slight twisting/pulling motion.
    – Use a plastic socket to install the copper washer.
    – Carefully slide the new O-ring for the fuel return connection
    onto the connection.
    – To remove rust particles on the fuel injector sealing surface,
    clean the fuel injector bore in the cylinder head with a cloth
    dampened with engine oil or rust remover. Do not damage the
    sealing flanges.
    – Replace the fuel injector shaft seal using the O-Ring Assembly
    Sleeve - T10377- .
    – Slide the fuel injector sealing cap on.
    – Slide the tensioning plate onto the fuel injector and make sure
    it is positioned correctly. Refer to
    ⇒ Fig. ““Tensioning Plate Installed Position”“ , page 163 .
    – Insert the fuel injector in the fuel injector bore.
    When installing the tensioning plate nuts, the nut could fall into
    the cylinder head. Work very carefully to avoid unnecessary
    work or damage.
    – Install the tensioning plate nuts -17- by hand and tighten them.
    Refer to
    ⇒ “2.2 Fuel System Component Overview”, page 160 .
    – Turn the sealing cap -19- to its installed position and tighten
    the bolts. Refer to in the
    ⇒ “2.2 Fuel System Component Overview”, page 160 .
    – Install the high pressure lines. Refer to
    ⇒ “4.4 High Pressure Lines”, page 179 .
    The “injector quantity calibration” and the “injection pressure calibration”
    for the new injectors must be must be programmed into
    the Engine Control Module (ECM) after replacing one or more
    injectors. Refer to "Guided Functions" in the vehicle diagnostic

    Attached Files:

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