Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Injectors

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the injector lines using a line or flare nut wrench.
  4.  

Remove the injector lines as a complete set. DO NOT attempt to bend or alter the configuration of the lines in any way. These lines are pre-formed for precise flow.

  1. Remove the injectors from the cylinder head using tool US 2775 or an equivalent deep socket.
  2.  
  3. Remove the injector heat shields from the cylinder head. This should be done as part of an injector replacement.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of an injector used on diesel engines

To install:
  1. Install new heat shields into the head with the concave portion facing down (as shown in the illustration).
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Make sure the heat shield is installed with the concave side down

  1. Install the injectors into the head, then torque to 51 ft. lbs. (70 Nm).
  2.  
  3. Connect the injector lines and torque the line nuts to 18 ft. lbs. (25 Nm). It will be necessary to use a crow's foot attachment on the torque wrench to properly tighten the fittings.
  4.  
  5. Connect the battery cable.
  6.  

 
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