Audi Parts Catalog Audi Accessories Catalog Audi Technical Articles VW-Audi Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
VW / Audi Fuel Injector Replacement
 
Bookmark and Share

Pelican Technical Article:

VW / Audi Fuel Injector Replacement

Peter Bodensteiner

Time:

1 hr

Tab:

$15 to $500

Talent:

***

Tools:

5mm Allen socket/key, utility knife, Carb cleaner, rags, small disposable cup or container, safety goggles and gloves

Applicable Models:

 
Audi A4 (1997-01)
Audi A4 Quattro (1997-01)
Audi TT (2000-04)
Audi TT Quattro (2000-04)
VW Beetle (1999-02)
VW Golf (2000-02)
VW Jetta (2000-02)
VW Passat (1996-00)

Parts Required:

Fuel injector gaskets, retaining clips, injectors

Hot Tip:

Remove the number 1 injector first and then drain the fuel rail to minimize fuel leakage during disassembly.

Performance Gain:

Clean, non-leaking injectors deliver fuel to the engine effectively; upgraded injectors deliver more fuel to support higher power levels

Complementary Modification:

Replace fuel pressure regulator, replace fuel filter, service intake manifold

In terms of a vehicle's fuel supply, the fuel injectors are where the rubber meets the road, so to speak; in other words, they are the devices at the end of the system of tanks, filters, pumps, and lines that actually deliver fuel to the intake manifold of the engine.

Each injector on the 1.8T is aimed directly at the three intake valves for that cylinder. The injectors are mounted at the ends of the intake runners, just before they lead into the cylinder head. The fuel rail is a metal pipe that supplies fuel to the injectors; fuel arrives at the fuel rail through a rubber hose that, in turn, connects to hard metal lines that run forward from the fuel tank. Fuel that doesn't leave the fuel rail through the injectors returns to the tank through a system that mirrors the supply lines, with rubber hoses leading to hard metal lines that lead back to the fuel tank.

The injectors are actuated electrical signals that originate at the car's ECU. Thus, each injector needs not only a fuel supply but also an electrical connection. In order to remove the injectors, we need to disconnect both.

You might need to do this job if you suspect that one or more of your injectors is not performing as it should. You also might need to do this project if you are pumping a lot of boost through your engine and you now require bigger injectors (i.e., ones that flow more fuel).

Make sure you've disconnected the battery at the negative terminal before you start. And, just as with the fuel filter, injectors, or any other component of the fuel system, it's best to relieve the fuel system of any pressure before you go opening it up. You can do this by opening the fuel filler cap, or by removing the fuel pump fuse from the car's fuse panel and then starting the car and allowing it to idle until it runs out of fuel. Also, be sure to use some protective gloves and goggles whenever you're working with fuel.

This photo gives an overview of the area where the fuel injectors reside.
Figure 1

This photo gives an overview of the area where the fuel injectors reside. To the driver's side of the valve cover you first see the four electrical connectors that plug into the fuel injectors. Just past those you'll see the shiny metal pipe that is the fuel rail, with the rubber supply and return hoses connected to it. Also visible are the four runners of the aluminum intake manifold. Each injector fits into a hole just before the end of each runner, aimed at the intake valves.

This double-zip tie can be cut to free up the wiring in preparation for moving it out of the way as you lift the fuel rail away from the intake manifold.
Figure 2

This double-zip tie can be cut to free up the wiring in preparation for moving it out of the way as you lift the fuel rail away from the intake manifold.

Two 5mm Allen-head bolts hold the fuel rail in place on top of the intake manifold.
Figure 3

Two 5mm Allen-head bolts hold the fuel rail in place on top of the intake manifold. The Allen socket won't fit between the fuel rail and the black coolant crossover pipe, so you will have to resort to other means if you encounter the same problem.

This Allen wrench fits between the two pipes.
Figure 4

This Allen wrench fits between the two pipes. Remove the two Allen bolts. It's a good idea to use a soft bristled brush and some brake parts cleaner to remove any dirt or debris around where the fuel injectors mount in the intake manifold.

The fuel rail can now be lifted up and away from the intake manifold.
Figure 5

The fuel rail can now be lifted up and away from the intake manifold. Apply even, upward pressure as you dislodge the fuel injectors from their ports in the manifold.

You may have lots of debris around the fuel injector ports
Figure 6

You may have lots of debris around the fuel injector ports--make sure to keep this stuff from falling into the intake manifold.

I placed some rags into the injector ports to keep the crud from falling in.
Figure 7

I placed some rags into the injector ports to keep the crud from falling in.

Use a flat-blade screwdriver to dislodge the metal retaining clips that secure the injectors to the injector bosses on the fuel rail.
Figure 8

Use a flat-blade screwdriver to dislodge the metal retaining clips that secure the injectors to the injector bosses on the fuel rail.

To remove the electrical connector, pull down on this metal clip (again using a screwdriver if necessary).
Figure 9

To remove the electrical connector, pull down on this metal clip (again using a screwdriver if necessary). Be careful not to lose the clip as you remove it, as it can spring away from you easily.

Pull the connector away from the injector body.
Figure 10

Pull the connector away from the injector body.

The electrical connectors are paired up using a plastic bridge, so you're best served to remove the connectors from the injectors in pairs, too.
Figure 11

The electrical connectors are paired up using a plastic bridge, so you're best served to remove the connectors from the injectors in pairs, too.

To remove the injector from the fuel rail, simply pull on it.
Figure 12

To remove the injector from the fuel rail, simply pull on it. Have some rags handy to catch any fuel that could leak out--I'd recommend starting with the number 1 injector (the one closest to the front of the car). Keep that end of the fuel rail elevated as you remove the first injector. Also note that the injector's top O-ring remained lodged in the fuel rail--make sure you get all the O-rings out.

This detail view of the fuel injector shows the O-ring that was removed from the fuel rail.
Figure 13

This detail view of the fuel injector shows the O-ring that was removed from the fuel rail. The screwdriver is pointing to the other O-ring. These two O-rings are different and are not interchangeable. All should be replaced before you reinstall the injectors.

Before you move on to the other injectors, tip the fuel rail down at the front end to drain as much fuel out as possible.
Figure 14

Before you move on to the other injectors, tip the fuel rail down at the front end to drain as much fuel out as possible. This will minimize leaks as you remove the other injectors. Here is the amount of fuel that came out of the fuel rail when I did this.

Once you have removed all the injectors, set the fuel rail on top of a rag to absorb any remaining drops of fuel that may escape.
Figure 15

Once you have removed all the injectors, set the fuel rail on top of a rag to absorb any remaining drops of fuel that may escape.

Here's one of the injectors, in all its crud-covered glory.
Figure 16

Here's one of the injectors, in all its crud-covered glory. In all likelihood, this injector has never been removed in more than 100,000 miles.

Spray a little carb cleaner on the metal end of the injector to remove the built-up carbon deposits, and then use a rag to wipe the carb cleaner off.
Figure 17

Spray a little carb cleaner on the metal end of the injector to remove the built-up carbon deposits, and then use a rag to wipe the carb cleaner off.

Here's a dirty injector next to one that has been cleaned with carb cleaner.
Figure 18

Here's a dirty injector next to one that has been cleaned with carb cleaner. Spray a little bit into the business end of the injector as well to remove any deposits there.

I cleaned up the body of the injector with some Simple Green, which is less aggressive and less likely to damage the plastic.
Figure 19

I cleaned up the body of the injector with some Simple Green, which is less aggressive and less likely to damage the plastic. A toothbrush helped remove grime from the nooks and crannies.

The clean injector is ready for its new O-rings.
Figure 20

The clean injector is ready for its new O-rings. Note the difference in dimensions between the two gaskets. You can now reinstall the injectors on the fuel rail and then mount the fuel rail to the intake manifold, tightening the Allen bolts to 7.5 ft-lb. When you prepare to start the car again, move the key to the "On" position. You may even be able to hear the fuel pump start up. Let the fuel pump work for a minute to make sure the fuel rail is filled before attempting to start the engine.

Bookmark and Share
Comments and Suggestions:
bazza Comments: Hi
I just want to thank you for a great to follow DIY.
May 26, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Jesse Comments: I have a 2002 jetta 2.0. Fuel injector 3 is faulty. Is the clunt for the injectors left to right? Or reverse. I don't wanna change all of them
March 17, 2016
  Followup from the Pelican Staff: clunt? I don't understand what you mean. If you are trying to identify cylinder order and location, cyl #1 is closest to the drive belts, then 4 is closest to the trans. - Nick at Pelican Parts  
Gorno Comments: I am not a mechanic, so this all may sound stupid; but I need your help. I have a 2002 VW Cabrio which sometimes has trouble starting.I hear the starter turning, but occasionally the vehicle fails to start and I have to turn off the ignition and try again. I *think* I resolved the problem by feeding the engine fuel revving the engine and turning off the ignition -before the extra fuel could be consumed at end of trip. I suspect this is reducing the recurrence of the problem. Luck so far. Which part is it that is the problem here?
February 27, 2016
  Followup from the Pelican Staff: When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume, quality and engine compression. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose. - Nick at Pelican Parts  
pj Comments: Could you possibly leave the injectors on the rail and clean them without taking them off and changing the gaskets? or atleast the one against the fuel rail. This is on an A4 B5 99 1.8t with 127k. I haven't noticed anything unusual and I don't have any codes. This would be just service to assure they were clean.
Thanks!
January 23, 2016
  Followup from the Pelican Staff: No, you should remove them to avoid debris getting in something you don't want it to. - Nick at Pelican Parts  
Ryan Comments: Hi,

My 1.8t has a slight idling misfire reading codes for cyl 2 &4. When swapping #1 & #2 coils and fuel injectors to see if the misfire would follow, I noticed that when looking down into the intake manifold after removing the injectors, #2 had significant carbon build up around the valves/ manifold. Is this a sign of a bad injector? If so can I just buy 1 new stock one to replace it?

Thank You,
Ryan
July 15, 2015
  Followup from the Pelican Staff: You can replace only one injector. Carbon may be from a faulty injector or bad valve guide. - Nick at Pelican Parts  
Kovics Comments: On an Audi A4 B5 with AEB Engine, the fuel injectors go into a plastic insert screwed into the intake manifold. The insert takes a 17 mm Allen bit. Do you know the torque for this insert?
July 6, 2015
  Followup from the Pelican Staff: I don't have the torque spec.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Rene169 Comments: Im having problems with starting the car just installed the transmission back in my 2003 Audi A4 1.8 cvt sedan is there a procedure that i have to preform the tcm was sent to get reflashed any info let please thank you Pelican.
June 22, 2015
  Followup from the Pelican Staff: Are there any fault codes? - Nick at Pelican Parts  
skeeter Comments: Nick
There is a plastic bridge between the injector electrical connections that pairs up connectors and has a twist tie. What is the object of these bridges and what could be the consequences if the bridge is broken
December 2, 2014
  Followup from the Pelican Staff: It is a harness mount. The harness will not be secure if it is damaged. - Nick at Pelican Parts  
skeeter Comments: what the object of the bridges between injectors and if broken what could happen
December 1, 2014
  Followup from the Pelican Staff: I don't understand your question. - Nick at Pelican Parts  
Zac Comments: Hi what's it mean if my injector spins by hand freely and easily? Doesn't the fuel rail supposed to prevent rotation or the o rings only I'm missing a lil and minor gas leak is evident - but hardly noticeable
November 16, 2014
  Followup from the Pelican Staff: It will rotate somewhat, this is normal. The retaining clip may not be engaged correctly. I see it in your photos, at the top of the injector. - Nick at Pelican Parts  
KG Comments: Hi im having serious challenges with my car its an Audi 1.8T 2005 model, when cold it runs smooth but as soon as it gets warmed up it start to hold back, then opens and holds back, this is seriously irritating especially when its on up hill, its really worse
October 24, 2014
  Followup from the Pelican Staff: I would start by checking the vehicle for fault codes. If the system is not working properly, a fault code will be set. This will be your best bet when diagnosing.


Then I would perform a fuel delivery system test. Check fuel pressure, volume and quality. - Nick at Pelican Parts
 
Taher Algharbawi Comments: I am located in Jeddah-Saudi Arabia.
I need to get 4 fuel injector P/N 0280 150 464 do you have them in stock how much the cost do you ship international.
August 16, 2014
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799. They can answer that question. - Nick at Pelican Parts  
Taher Algharbawi Comments: Do you ship parts international?
August 15, 2014
  Followup from the Pelican Staff: I am not 100% sure. Give our parts specialists a call at 1-888-280-7799. They can help you. - Nick at Pelican Parts  
Danu Comments: hi. what size are the o rings for the fuel injectors? thanks
July 4, 2014
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799. They can help you find the right O-rings. - Nick at Pelican Parts  
DP Comments: I just changed out the four injectors on my 2002 A4, 1.8T and this actually made the engine run worse. Any Ideas of what would cause this? There was evidence that the 2 & 3 injectors were leaking fuel prior to the repair. Also, the engine used to run smooth until it warmed up, then it developed a misfire, but would then run smooth again when cooled off.
June 2, 2014
  Followup from the Pelican Staff: You could have a vacuum leak or when replacing the injectors cause debris to fall into the injector holes. If the problem was present before the repair, you may have an engine misfire. I would try to isolate the misfire to see which cylinder is the problem. - Nick at Pelican Parts  
Freedom 02 Comments: turns out my problem was not the coil, spark plugs or the fuel injectors it was the ignition that caused the misfire on #3 cylinder replaced the ignition and the cars runs good and no more misfire.
January 12, 2014
  Followup from the Pelican Staff: Thanks for the follow up. We appreciate it.
- Nick at Pelican Parts
 
Freedom 02 Comments: my 1997 audi a4 quattro 1.8 has a #3 cylinder misfire I replaced the coil, spark plugs and cleaned the fuel injectors even swap the #3 cylinder to #1 cylinder and its still showing that #3 has a misfire what else could be causing this any suggestions?
January 1, 2014
  Followup from the Pelican Staff: Check the base engine. Static and dynamic compression. - Nick at Pelican Parts  
Matt Comments: I have a 2005 Passat 1.8t. Is this instruction above the right procedures for ym injectors? thanks Matt Miller , Moraga CA
December 28, 2013
  Followup from the Pelican Staff: This article applies to:
Audi A4 (1997-02)
Audi TT (2000-04)
VW Passat (1996-00)
VW Golf (2000-02)
VW Jetta (2000-02)
VW Beetle (1999-02) - Nick at Pelican Parts
 
Bobby Comments: Question about injector o-rings: in picture 13 and in picture 20 you make it a point to note there are two different size o-rings for the fuel rail side and the intake side but when I click to order parts, the list says I need 8 of part 035-906-149-A-M213 which have me using the same size o-rings for the top and bottom of each injector. Are these the fuel rail side or intake side o-rings? Thanks.
June 30, 2013
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799. They can help you sort out your O-ring questions.- Nick at Pelican Parts  
Rookie Comments: Hi Can I ask about the Audi 1.8t fuel rail photos. Could you explain the flow of the hoses going to and from the fuel rail. There is a small diameter soft braided hose going to the regulator, a large solid line coming from the bottom of the regulator and a large solid line coming from the other end of the rail itself. Rookie question. Why isn't there just one feed line to the rail.

Thanks
January 4, 2013
  Followup from the Pelican Staff: Supply, return, and regulation, This system recirculates for cooling and to maintain system pressure. Audi made an internal management/engineering decision to use this BOSCH system. - whunter  

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Fri 12/9/2016 02:02:04 AM