Disconnect electrical connector -1 for air mass meter -G70-. Unscrew bolt -3 and release exhaust gas pressure sensor 1 -G450--pos. 4- on the air duct pipe. Unplug and unplug connector -2 for exhaust temperature sender 4 -G648- at air duct pipe. Remove the air hose with air mass meter -G70- by unclamping the hose clamp -5- and loosening the fasteners -arrows-.
Disconnect vacuum line -1-. Remove the air housing. filter and disconnect the plug connector -2 of the air bypass valve on the reverse side. filter -N275-.
Disconnect plug connector for glow plug for cylinder 1. Disconnect plug connectors -1...7- and release wiring harness using lever -80 - 200-.
For re-installation, note the correspondence of the high pressure lines to the injection nozzles. Loosen the union nuts of the high-pressure lines -1...6- using a 17 mm insert -VAG 1331/6- and a socket wrench attachment -T40055-.
Remove the fuel return pipes. lines from the injection nozzles; to do this, pull the release bolt upwards -arrow-. Remove the controlled check valve -1- from the bracket and place the valve with the connected fuel hoses to the side. Unscrew the pressure reducing valve bracket.
The following pictures show the left cylinder head. Unscrew the bolts -arrows- for the injection nozzle covers. Pull the covers up and turn 90°. Unscrew the bolts -arrows- for the injection nozzles. Reinstallation of injection nozzles is only permitted on the cylinder on which they were originally installed. Mark the correspondence of each injector to the cylinder. Remove the injection nozzles using a puller -T10055- with adapter -T10055/1 -. Unscrew the cylinder head cover bolts -arrows- crosswise. Remove the bolts and remove the cylinder head cover.
Installation
Install in reverse order. Replace the damaged cylinder head cover gasket. If the gasket is damaged, replace the cylinder head cover bolts. Hose fittings, air pipes and hoses must be cleaned of oil and grease before installation. Secure all hose connections with hose clamps of the appropriate series. To ensure reliable fastening of the air hoses to the fittings, the threaded connections of already used clamps should be treated with a rust remover. Clean the seating surfaces; There should be no oil or grease on them. Tighten the cylinder head cover bolts. Install the injectors, high pressure lines, upper part of the intake manifold, air housing. filter and exhaust gas pressure sensor 1 -G450-. Check the fuel. systems for tightness.
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