Dismantling the nozzles
General provisions
Depressurize the hoses at the test connector on the fuel distribution line. Place a container under the spilled fuel.
With the valves removed, close the openings in the intake manifold to prevent dirt from entering.
Check the rubber o-ring on the injector. Replace damaged or worn ring.
In order to install the injectors easier and without damage, lubricate the O-rings with petroleum jelly or ATF. Do not use other means!
The nozzles must be inserted into the distribution pipeline in a certain position. Possible twisting along the longitudinal axis leads to a deterioration in the performance of exhaust gases. In order to bring the nozzles into the correct position, metal tongues are placed on the distribution pipe at the height of each nozzle, which allow only one possible mounting position.
When installing, do not forget about the ground connection.
After installation, check the fuel system for leaks.
Multec-S
Disconnect the battery ground wire.
Depressurize the hoses at the test connector on the fuel distribution line. Place a container under the spilled fuel.
Remove the upper part of the intake manifold, see the engine chapter under «Removing the cylinder head cover of the 16V engine».
Remove from the clamps of the brackets and disconnect the wire connectors of the camshaft position sensor and pulse sensor.
Disconnect the wire connectors on the injectors and remove the wiring harness from the distribution pipeline.
Unscrew the fuel distribution line from the bottom of the intake manifold.
Remove the fuel distribution line with injectors from the bottom of the intake manifold.
Close the openings in the intake manifold to prevent dirt from entering.
Use a small screwdriver to depress the safety clip between the injector and the fuel distribution line and remove the valve from the fuel distribution line.
Simtec
Remove the crankcase ventilation hoses from the cylinder head cover.
Remove the air intake hose.
Remove the cable from the throttle body.
Disconnect the wire connector on the idle speed control
Use a small screwdriver to press back the safety clips of both outer nozzles and remove the cable duct.
Remove the vacuum hose from the fuel pressure regulator. Also unscrew the ground wire on the pressure regulator
Unscrew the fixing bolts on the fuel distribution line and lift the fuel distribution line together with the injectors upwards.
The photo shows a 16V 1.8 / 2.0 liter engine. After opening the cable channel, the connectors of the wires of the injection valves are visible. To test voltage as described on page 92, insert two thin needles into the connecting wires of the valve to be tested. Connect the LED voltage indicator. Start the engine: the voltage indicator LEDs should flash.
Use a small screwdriver to depress the safety clip between the injection valves and the fuel distribution line and remove the valves from the fuel distribution line.
During installation, align all safety clips in such a way that perfect contact of the connector strip with the injectors is ensured.
Removing the throttle valve
Multec-S
Drain the coolant into a container.
Dismantle facing of the engine on a cover of a head of the block of cylinders.
Remove the upper part of the intake manifold, see the engine chapter under «Removing the cylinder head cover of the 16V engine».
Remove the cable duct from the clips and set aside.
Remove the DIS ignition module, see ignition chapter.
Remove the fuel tank vent valve from the bracket and set aside.
Disconnect the vacuum hose from the fuel tank vent valve to the bottom of the intake manifold.
Unscrew or remove the vacuum hoses or lines to the intake manifold pressure sensor, secondary air changeover valve, and brake booster from the top of the intake manifold.
Remove the air duct from the bottom of the intake manifold and from the throttle body and set it aside.
Unscrew the throttle cable control bracket from its nozzle and unhook the cable.
If necessary, to improve accessibility, loosen both hose clamps on the connecting hose and twist them.
Unscrew the four fixing bolts of the throttle valve pipe and remove the gasket.
Depressurize the hoses at the test connector on the fuel distribution line. Place a container under the spilled fuel.
Remove the fuel injection line from the fuel distribution line. To do this, press the distribution fuel line in the opposite direction.
Unscrew the fuel return line at the pressure regulator. To do this, press the pressure regulator in the opposite direction.
Twist the throttle valve slightly and remove the coolant hoses. Mark the installation position.
Disconnect the wire connectors at the throttle potentiometer and idle speed control.
Remove the throttle body and plug the hole in the intake manifold.
Clean sealing surfaces and remove gasket residue.
After installation, fill in the coolant and bleed the cooling system.
Simtec
Drain the coolant into a container.
Remove the air intake hose.
Disconnect the crankcase breather hose from the cylinder head cover.
Disconnect the wire connector at the idle speed control.
Unhook the throttle cable and remove it from the bracket.
Remove the vacuum hose to the throttle valve pressure regulator.
Remove the coolant hoses and crankcase breather hose from the throttle body
Disconnect the wire connectors at the throttle potentiometer.
Unscrew the four fixing nuts of the throttle valve pipe.
Remove the throttle body from the intake manifold and plug the hole.
Clean sealing surfaces and remove gasket residue.
After installation, fill in the coolant and bleed the cooling system.
Lambda probe (arrow) screwed directly into the exhaust manifold. Everything you need to consider when installing a lambda probe is given in the text below.
Removing the throttle potentiometer
On Simtec vehicles, the throttle potentiometer is easily accessible and secured with only two screws on the throttle body. But in vehicles with Multec-S, the throttle body must first be dismantled.
Disconnect the wire connector and unscrew the potentiometer.
Lubricate the bolts with protective compound during installation.
Removing the idle speed controller
Simtec: Disconnect the wire connectors at the intake air temperature sensor and at the air mass meter.
Disconnect the crankcase breather hose from the cylinder head cover.
Multec-S: remove the throttle body.
For all models: Disconnect the wire connectors at the idle speed control.
Unscrew the idle speed control from the throttle valve. Close the hole.
Clean sealing surfaces and remove gasket residue.
With Multec-S, note the mounting position of the idle speed controller. The electrical connection on the regulator must point downwards.
Removing the pressure regulator
Relieve the fuel pressure in the fuel lines through the test connector.
Multec-S: remove the cylinder head cover.
Disconnect the wire connector in the area of the pressure regulator.
Remove cable duct from clamp and set aside.
Unscrew the fuel return line from the pressure regulator. At the same time, press the pressure regulator in the opposite direction.
Remove the vacuum hose from the pressure regulator.
Unscrew the mounting screws and remove the pressure regulator together with the bracket.
Simtec: Remove the crankcase breather hose from the cylinder head cover.
Remove the vacuum hose from the pressure regulator.
Remove the clamp from the pressure regulator.
Carefully remove the pressure regulator from the fuel distribution line.
For everyone: Use new O-rings when installing.
Replacing the lambda probe
The probe thread is lubricated with a special paste that prevents jamming. It consists of liquid graphite, which burns during operation, and glass beads. The new probe is equipped with this grease, the threads of the old one must be lubricated with it (Ore1-No. 19 48 602).
Warm up the engine. The lambda probe must only be removed when the engine is warm.
Disconnect the lambda probe wire connector in the engine compartment. The connector is located in the mount on the gearbox.
Unscrew the lambda probe from the exhaust manifold or from the front exhaust pipe.
Protect your hands from burns (gloves, rag).
When mounting, tighten the probe to 30 Nm.
Pay attention to the wiring.
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