Contents: Removal ⇓ Installation ⇓
Removal
1. Disconnect the ground cable from the battery.
Warning! This will erase the engine fault memory or the radio security code. Before disconnecting the battery, read the instructions in Section Removal and installation the battery.
2. Reduce fuel pressure.
3. Remove the intake hose between the air filter and the throttle body.
4. Disconnect the throttle linkage from the throttle lever.
5. For easier dismantling, remove the intake manifold housing "1", having first disconnected the vacuum lines and marked them with adhesive tape to facilitate installation.
6. Disconnect the vacuum hose from the fuel pressure regulator.
7. Disconnect the plugs "3" of the injection valves and put the cable harness aside.
8. Disconnect the supply and return fuel lines "2" on the fuel line, having first loosened the clamp.
Warning! The fuel in the pipeline is under pressure. To protect against splashing, cover the pipeline with a rag.
9. Unscrew the fuel distribution line mounting bolts "4".
10. Remove the distribution line "4" with injection valves "5".
Caution! Remove the distribution line carefully so that the injection valves do not fall out or get damaged.
11. Remove the injection valves from the distribution line.
12. Remove the insulators from the valve holes.
Installation
Caution! Injection valve rings, gaskets and insulators must always be replaced.
1. Insert the injection valves with new O-rings into the upper part of the distribution line. Pre-coat the seals with a small amount of oil.
2. Insert insulators into the valve holes.
3. Install the fuel distribution line with injection valves into the cylinder head.
4. Check that the injection valves can be turned easily. If not, remove the valves again and check the position of the O-rings.
5. Turn the injection valves so that the plugs are facing upwards.
6. Install the fuel distribution line mounting bolts and tighten them securely 25 Nm.
7. Attach the vacuum hose to the fuel pressure regulator.
8. Connect the supply and return pipelines and secure with clamps.
9. Route the cable harness to the injection valves and connect the plugs.
10. Install the intake manifold housing with new gasket and screw on with force 25 Nm. Put on the vacuum lines according to the marking.
11. Connect the throttle actuator to the throttle lever.
12. Place the inlet hose onto the throttle valve pipe and secure with a clamp.
13. Connect the fuel pump plug and install the rear seat.
14. Connect the ground cable to the battery.
15. If available, set the time on the clock and set the security code for the radio receiver.