WARNING

This is a text/photo guide written by myself, to aid other members in the removal of the Fuel Injectors and Fuel Rail components, with reference to guides for the removal of the Air Cleaner Housing and Throttle Body components.

I have written this guide as precise as i can, and mentioned any necassary safety procedures to under take (if any).

I take no responsibilty for any damage or injury caused to vehicles or person(s).

So lets begin!

(This guide involves working with the fuel system, take all precautions necassary when working with fuel and electrics etc!)

1.

Firstly you will need to remove the Air Cleaner Housing unit, along with the Accelerator Cable and Throttle Body.

The link to my previous guide can be found below:

http://www.clubpolo.co.uk/forum/index.php?showtopic=82368

2.

Once you have done the previous stages, you will now need to shut off the power supply and fuel pressure.

(Very Simple)

>Disconnect the battery negative lead, and position it away from the terminal.

>Unplug the injector harness connectors, labelling them 1-4, to aid correct fitment later.

(YOU MUST LABEL THE CONNECTORS IN THE ORDER YOU REMOVE THEM, I.E 1,2,3,4)

>Unclip the harness clips from the top of the fuel rail, and lay the harness and injector wiring to one side

3.

Now you will need to depressurise the fuel system.

(Again this is very easy!)

(Make sure you have disconnected the battery negative terminal first!)

>Identify and remove the fuel pump fuse from the fuse in the fusebox.

>The fuse for me was F18 , and its a 20A, colour was YELLOW

4.

With the fuel pump now shut down, you can begin to disconnect the necassary fuel lines.

>Diconnect the vacum hose from the port on the bottom of the fuel pressure regulator.

(This is the small component on the right hand end of the fuel rail)

>Slacken and disconnect the fuel supply and return hoses from the end of the fuel rail.

(Carefully note the positions of the hoses - the supply hose is marked with a black or white arrow, and the return hose is marked with a blue arrow.)

(These are held on tight with clips, prise them off with a screwdriver and use force! Use rags to soak up fuel spillage)

5.With the fuel supply now depressurised and manually cut off, you can now begin to remove the fuel rail component.

>Slacken and remove the fuel rail mounting bolts, then carefully lift the rail away from the inlet manifold, together with the injectors.

>Recover the injector lower O-ring seals as they emerge from the manifold...if you feel necassary.

You are now left with the fuel rail with the fuel injectors, and fuel pressure regulator connected.

Fuel Pressure Regulator

>To remove individual injectors siimply remove the retaining clip and pull off.

(DO NOT loose the o-ring seals, and mark each njector 1-4 to correspond with the position you removed them from!)

>To remove the Fuel Pressure Regulator, slide out the U-pin and pull off carefully.

6.

Refitting is the reverse of removal.

>Renew any O-ring seals if they appear to be worn

>Ensure all injector retaining clips are securely seated

>Check the fuel supply and return hoses are connected correctly!

>Check that all vacuum and electrical connections are remade correctly and securely

7.

Now you have reconnected the fuel system, you can go and put the fuel pump fuse back in position.

8.

Now reconnect the battery negative terminal

(ON COMPLETION CHECK EXTENSIVELY FOR FUEL LEAKS BEFORE PUTTING THE VEHICLE BACK INTO SERVICE!!)

Thankyou, JNS :-D

Edited 23 October, 200718 yr by VW_Technik

Can someone please PIN this guide.

Thanx, JNS

? god damn it

STICKY?

sweet mate:)

Great guide...took my injectors off and sent them to be serviced...fuel economy back to normal :-)