Fuel Injector Insert

To replace the Fuel Injector Insert or the insert O-rings:

CIS-E Fuel Injector Insert:

1. Remove the fuel injectors by pulling them straight out, forcing them out of the O-rings that hold them. Leave the fuel lines attached to the injectors. Pull straight and pull only on the injectors themselves, do not pull on the fuel lines.

NOTE: Some force is required to remove the injectors, and an inexpensive special tool is available which makes the job easier. It fits under the injector fitting and uses a screwdriver for leverage, prying the tool and the injector straight out. One such tool is VOLKSWAGEN special tool # US 1123/4.

2. The inserts have an internal hex socket and are removed using a 12mm or 13mm hex wrench depending on application. Loosen and remove the inserts.
3. Clean the threads of the upper insert.
4. Clean and dry the injector insert receiving ports on the engine.
5. Replace all the O-rings on the inserts.
6. Apply thread locking compound (VW D6 or equivalent) to upper injector insert threads.
7. Lubricate insert O-rings and install inserts into receiving ports.
8. Torque upper injector insert to:

15 ft.lb. (20 Nm)

9. Replace the thick rubber O-rings on the fuel injectors.
10. Lubricate the fuel injector O-rings and press the injectors into the insert until the O-ring is fully seated in its groove.