Contents: Removal ↓ Installation ↓
Removal
Fig. 2.73. Fuse block in the front panel
Remove the SD34 fuse (fuel pump) from the fuse box on the right side of the front panel (Fig. 2.73).
Note: Removing fuse SD34 interrupts the power supply to the fuel pump for safety reasons, as it would otherwise turn on when the driver's door is opened.
Warning: The fuel system is under pressure, to avoid injury and skin contact, wear protective glasses and gloves. Before disconnecting the hoses, wrap the connection with a rag. Then relieve the pressure by carefully loosening the connection.
Fig. 2.74. Fuel line
Disconnect fuel line 1 and the line to electromagnetic valve 1 of absorber 3 (Fig. 2.74).
Cap hoses and lines to prevent dirt from entering the fuel system.
Remove the upper and lower intake manifold sections.
Remove the mounting bracket and spacer sleeve from the injector.
Fig. 2.75. Installing a puller on an injector
Place the puller on injector 1 (Fig. 2.75). Make sure that the puller jaws fit into the recesses on the injector.
Tighten the puller knurled nut by hand.
Fig. 2.76. Installing the mandrel on the puller
Screw the mandrel to the puller (Fig. 2.76).
Remove the injector from the cylinder head by gently tapping on the mandrel.
Installation
Fig. 2.77. Cleaning the cylinder head holes with a nylon cylindrical brush
Clean the cylinder head bore with a nylon cylindrical brush (Fig. 2.77).
Fig. 2.78. Nozzle cleaning location
Thoroughly clean the injector in the seal area. Remove any deposits (carbon) with a metal brush (Fig. 2.78).
Carefully cut the gland with a knife.
Clean the oil seal groove.
Fig. 2.79. Installing the mounting tip
Place the mounting tip with a new seal 1 on the injector 2 (Fig. 2.79).
Use a drift to push the seal further onto the valve core.
Turn the mandrel over and push the seal into the groove.
Fig. 2.80. Installing the calibration sleeve on the injector
Press the calibration sleeve with a slight rotation (about 180°) onto the nozzle until it stops (Fig. 2.80).
Remove the calibration sleeve again by turning it in the opposite direction.
Press the calibration sleeve with a slight rotation (about 180°) onto the injector until it stops.
Remove the calibration sleeve again by turning it in the opposite direction.
Replace the O-ring on the injector and spacer sleeve.
Before installation, lubricate the O-rings with clean engine oil.
Note: Do not lubricate the oil seal with engine oil.
The original can be found at: www.vwmanual.ru
Insert the injector into the cylinder head.
Note: The nozzle should be inserted easily, otherwise wait until the seal is sufficiently compressed.
Install the mounting bracket and spacer sleeve.
Further installation is carried out in reverse order.
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