Volkswagen Workshop Service and Repair Manuals > Golf Mk5 > Power unit | 4-cylinder injection engine (1.4 l direct injection engine, turbocharger and supercharger) | Mixture preparation system, electronic inj.,Gas | Injection system | Assembly overview

Assembly overview - fuel rail with injectors

1 -

O-ring

Renew.

q	Before installing, moisten lightly with clean engine oil.

2 -	Spring element

q	Renew each time after removing lower part of intake manifold.

q	Ensure proper seating on injector.

3 -	Injector, cylinder 4 -N33-

q	Injector, cylinder 1 -N30-

q	Injector, cylinder 2 -N31-

q	Injector, cylinder 3 -N32-

q	With Teflon seal and support washer.

q	After removing injector, Teflon seal and support washer must be renewed → Chapter.

q	Removing and installing injectors → Chapter.

4 -	Vacuum hose

5 -	Return line

q	From high-pressure pump.

q	Blue or with blue marking.

q	Secure with spring-type clips.

q	Check for secure seating.

6 -

20 Nm

7 -	Pressure limiting valve

q	Renew removed valve.

q	Before installing lightly moisten O-rings with clean engine oil.

q	Press in by hand using an 8 mm hexagon key.

8 -	Intake manifold lower part

q	To remove and install: use Holder for 5/16 inch bits -V.A.G 1766/2- and Bit -3320/2- → Fig.

q	To remove, removing and installing regulating flap control unit -J808-, throttle valve module -J338- and intake manifold → Chapter.

Removing and installing lower part of intake manifold

To remove and install the securing bolt -arrow- use Holder for 5/16 inch bits -V.A.G 1766/2- and Bit -3320/2-.

Checking function of intake manifold flap

–	After installing a new lower part of intake manifold, remove retaining clip -arrow- for vacuum positioning element.

–	Connect hand-operated vacuum pump -VAS 6213- as shown.

–	Generate a vacuum and check function of vacuum positioning element on lever arm.

Note

When intake manifold is removed, the function of intake manifold flap can be checked simultaneously.

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