VW 2.0T Fuel Injector Teflon Seal Hack

Around New Years, Uncle Jim and I set out to clean his intake valves on his VW Passat. When we pulled the intake manifold two fuel injectors came out with the manifold. Now we were committed to rebuilding the injector seals.

Coked Up Intake Valves

Because the gas in injected directly into the cylinder the intake valves don't get cleaned by the gas the way it does in a typical engine. This means that every 50K miles or so the intake manifold needs to be removed and all the oily deposits need to be scraped off. After the engine is reassembled and the car is taken out for a test drive, all the missing horses are found.

Improvised Tools

Here is the pencil tip and the refrigeration fitting that we used to push the white
telfon seal onto the injector.

Close-up View

You can see the raised edge that we are talking
about in the video.

This is a little video we put together to show our work around not having the $250 special tools used to work on fuel injectors.