Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Pull injector connector off fuel manifold.
• ‒ Remove intake hose and throttle valve housing.
• ‒ Pull return hose off fuel manifold.
• ‒ To prevent fuel spray, cover pressurized fuel supply hose with a cloth and pull off fuel manifold.
• ‒ Pull fuel pressure regulator vacuum hose off junction piece.

Vehicles with automatic gearbox

• ‒ Remove vacuum booster.

• ‒ Remove fuel manifold securing screws.

Note:

The ratchet and socket SW5, with 1/4' drive, are particularly suitable for removing the socket head screws.

• ‒ Pull fuel manifold with injectors out left, facing direction of travel.

• ‒ → Remove screw -1- and lever upper part of fuel manifold -2- of fuel manifold -3- at point indicated by arrows.

• ‒ → Clamp threaded end of socket head screw (M6) in a vice and press out injectors.

Installing

Note:

Renew injector damaged seals/gaskets and O-rings.

• ‒ Place gasket on fuel manifold upper part.

• ‒ → Insert injectors into fuel manifold upper part and moisten O-rings -arrows- with oil.
• ‒ Press fuel manifold upper part with injectors into the fuel manifold.

• ‒ → Tighten screw -1- to 10 Nm.
• ‒ Place fuel manifold on intake manifold and tighten securing screws to 10 Nm.
• ‒ Connect fuel pressure regulator vacuum hose to junction piece.
• ‒ Connect fuel supply and return hoses and secure with spring-type clip.
• ‒ Attach connector for injectors.
• ‒ Install vacuum booster (if fitted), throttle valve housing and intake hose.