I have done this before, says the man watching fuel spill out from underneath the intake manifold! About 70,000 miles ago I had to replace the fuel injector seals on my 2010 VW Jetta. It’s a Wolfsburg Edition so it has the 2.0T motor in it. I’ve had the intake manifold fail, it was out of warranty when that happened, but then VW recalled it. They did not give me a refund for the price of the part due to the fact I did it myself and only had a receipt for the part.
Anyway, that happed at around 40k, then the injector seals started leaking at around 70k. Now here we are at 140k and the injector seals are leaking again! I don’t think I did anything wrong while putting them in the first time, if you happen to see something incorrect in this write up, please let me know.
This is how you replace the injector seals:
First you need to get your parts; you will need the injector seal kit and a means to pull the fuel injectors. I invested in the Scwaben Fuel Injector Puller kit. It made this job easy!
Now, pull the plastic cover off of the top of the motor, this will expose the coil packs, the fuel lines, and some vacuum lines that will need to be removed.
Remove the one T30 Screw and the 10mm bolt that is holding the plastic bracket for the fuel line. Once this is un-bolted, you can move it out of the way.
Next you will want to deal with the (Vacuum Solenoid?) that is attached to the top of the throttle body. Remove the vacuum line and electrical connections from the solenoid.
Remove The Clamp
Move out of the way
Next, you will want to remove the sensor that is attached to the throttle body. It is held in with a Phillips head screw.
Remove the sensor
Remove the vacuum line that goes from the intake manifold to the head.
I removed the coolant hose that was in my way. I had to fill up the coolant when I was done, but it made accessing the manifold bolts easier, it also exposed the bolts that hold a bracket that was in the way and needed to be removed as well.
Remove these two bolts so that the bracket will then come out.
There are a slew of electrical connectors that are underneath the throttle body and to the right as you are looking at the motor. I disconnected them all in an attempt to get to the pesky M bolt that holds the bracket for the intake manifold to the block. Not sure that it was necessary but it was not difficult to do.
Next is to disconnect the fuel line from the high pressure pump and from the fuel rail.
Remove This Screw
Remove the line from the High Pressure Fuel Pump
And From the Fuel Rail
At this point there is one more thing to do before unscrewing the intake manifold, you need to take the bracket off that is underneath the intake manifold. Maybe if you have the car on a lift this is not a problem, but in your driveway it definitely is. I tried to get a picture of it but could not get a camera in there. This thing is a pain to remove. I believe the bolt that is directly under the manifold is a 13mm bolt. You would think you could just undo this and pull the manifold up and over, but it doesn’t work. You will need the M bolt to remove it. It’s like a male 12 point socket. This bolt is on the block and is very difficult to get to. Maybe if you remove the intake hoses it would be easier. I might try that if I need to do this again!
Now you can remove the T30 screws that hold the intake manifold to the head. I believe that there are 7 of them. Might be 8, it’s been a while since I’ve done it.
Pull the intake manifold off the head, this will expose the fuel injectors.
Oh look! There’s my bad injector seal!
On the left there is a chunk missing from it
Disconnect the electrical connectors from the fuel injectors.
Use the Schwaben fuel injector puller kit to remove the injectors. On piece slides over the injector and the other slides on with a bolt, tighten the bold until the injector comes out.
Slide this over the fuel injector
Then this piece will slide over the whole unit
Use a ratchet to pull out the injector, it’s just like a pully puller
Comes out like magic!
Once you get the injector out, you will want to put the seal kit on. Remove the old nozzle seal. I just broke them off.
I used a screwdriver to break it
Remove the metal piece that keeps the injector in place.
This piece just slides off
I used some throttle body cleaner to clean the injectors.
Put the new metal piece on.
Then the new nozzle seal. There are tools in the Schwaben kit for this but I found it easier to just slide it over onto its spot.
I just stretched this seal over the injector
And Slid it into place
Take the old seal on the other end off and remove the plastic guard.
Put the new guard on and slide the new seal in place.
Install the plastic guard first
Then the seal
Install the injector back into its spot. It may be hard to get in, I used a soft hammer to tap it into place. Be careful, there is a slot where the electronics slide into that needs to be lined up correctly.
Put the new metal rings on.
Re-assemble! It is the opposite of the disassembly procedure.