Contents: Removal ↓ Installation ↓
The valves inject fuel intermittently: for each revolution of the crankshaft, half of the fuel required for one stroke is injected.
The fuel injected by the valve is cone-shaped. After injection, the valve closes hermetically. Leaky valves are the cause of poor starting of a hot engine.
Faulty valves cause the engine to run spontaneously after the ignition is turned off, which will lead to its failure.
Removal
4-cylinder engine
1. Remove the air filter together with the filter element (see Fig. Air filter).
2. Remove the air intake duct.
3. Disconnect the injection valve connectors from the ignition distributor.
5-cylinder engine
1. Remove the engine crankcase ventilation hose.
The original can be found at: VWManual
2. Remove the fuel supply and return lines from the fuel distributor.
3. Disconnect the vacuum hose from the fuel pressure regulator.
4. Unscrew the 5 mm Allen screws of the fuel distributor. Remove the fuel distributor together with the valves to the right, in the direction of travel. Unscrew the screw (1) and remove the upper part of the fuel distributor (2) from the fuel distributor (3).
7. Clamp the threaded portion of the 6mm Allen screw in a vice and push out the injection valve.
Installation
Caution! Replace damaged sealing rings or gaskets, as well as injection valve rings.
1. Install the gasket (indicated by arrows) on the top of the fuel distributor.
2. Insert the injection valves with new rings into the upper part of the fuel distributor. Before installation, lubricate the rings with a thin layer of clean engine oil.
3. Insert the upper part together with the injection valves into the fuel distributor.
4. Tighten the screw (1) to a torque of 10 Nm – see fig. in point 4.
5. Install the fuel distributor onto the intake manifold and tighten the mounting screws to a torque of 10 Nm.
6. Attach the vacuum hose to the fuel pressure regulator.
7. Attach the fuel supply and return lines. Connect the black fuel supply line to the fuel distributor, and the blue fuel return line to the fuel distributor and pressure regulator.
8. Connect the injection valve plug.
9. 5-cylinder engine: Install the engine crankcase ventilation hose and secure it to the oil filler neck. Make sure there is sufficient distance to the throttle valve pipe.
10. Install the air intake duct so that the marking arrows on the air duct and the branch pipe match (see Fig. Air filter).
11. 5-cylinder engine: Install the air filter together with the filter element (see Fig. Air filter).
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