Volkswagen Parts Catalog Volkswagen Accessories Catalog Volkswagen Tech Information Volkswagen Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Bookmark and Share

Pelican Technical Article:

Fuel Injector Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$550

Talent:

***

Tools:

5mm Allen, pliers, flathead screwdriver, rags

Applicable Models:

VW Golf GTI (2000)
VW Golf GTI 1.8T (2002-05)
VW Golf GTI 20th Anniversary (2003)
VW Golf GTI 337 (2002)
VW Golf GTI GLS (2001)

Parts Required:

New injectors, White Lithium grease

Hot Tip:

Check for flooded cylinders

Performance Gain:

Better-running engine, improved fuel mileage

Complementary Modification:

Replace worn out hoses

If your car is starting to run rough, getting horrible gas mileage or has an error code, there is a good chance it is time to replace the fuel injectors. Modern fuel injectors are made of plastic and we do not recommend having them serviced or rebuilt. Older mechanical injectors opened by fuel pressure alone and were easier to service; newer injectors are made of plastic, need an electronic pulse from the ECU to open and are better replaced than sending them out for service.

A properly working injector will send a precise amount of atomized fuel into the induction system at a designated time. A weak or improperly working injector can do everything from send no fuel, to leak raw, non-atomized fuel into your engine.

If you are going to be replacing your injectors, the first step is to prep the car. I like to tell people to pull out the fuse for the fuel pump and then try to start the car. The car will turn over and then die. Do this about 2-3 times - it will help drain excess fuel out of your system, also open the gas cap to help depressurize the system. Then, make sure that the car has cooled down; you don't want to be working with gasoline when the car is hot.

Have a fire extinguisher handy, there will be some spillage of fuel as it's nearly impossible to prevent. Also, wear chemical resistant gloves if you don't want to get any gasoline on your hands, and make sure that you have plenty of paper towels or rags to help you clean up. Perform the injector removal in a clear, open, and well-ventilated space, and it may not hurt to have an assistant around in case there are any problems.

You are going to be opening holes that go into the engine so before you begin get a can of compressed air and blow all the dust and debris away from the injector ports.

Open the gas cap to relieve any residual pressure.

Disconnect the four wiring harnesses from the injectors by squeezing in the two clips on each harness and pulling straight up.

Lay the connectors on the top of the engine and unclip the plastic wiring tray from the fuel rail.

There are two fuel lines connected to the rail; the supply line and the return line. Label and disconnect the lines. Be prepared to catch the small amount of fuel that will spill from them.

Disconnect the small hose from the fuel pressure regulator at the end of the fuel rail.

Remove the two 5mm Allen bolts holding the fuel rail to its mount.

With everything removed pull the injectors from their ports. They pull straight out on the angle they are inserted in. There are only held in by friction at this point and you will feel them "pop" when they release. Set the injectors and wiring harness on the top of the engine.

Be sure to put a few rags in the open holes in the manifold to prevent anything from falling into the engine. If you drop something into this hole you must get it out before going any further, this hole goes directly into the cylinder head and will cause catastrophic damage if left in!

The injectors are held on by metal clips; they can be pried or pulled off the rail. Next, you can remove the injector from the rail by wiggling it out, it is just held in by the O-ring at this point.

New injectors come complete with new O-rings. Apply a small amount of White Lithium grease to the O-rings and reinstall.

If you have had an injector that has been leaking heavily it can be a good idea to remove the coils and plugs to drain the combustion area of the extra fuel. While most of the fuel will drain out pass the piston rings, a severely leaking injector can cause hydro lock. It is easy to remove the plugs and can be cheap insurance.

You are going to be opening holes that go into the engine so before you begin get a can of compressed air (yellow arrow) and blow all the dust and debris away from the injector ports (red arrows).
Figure 1

You are going to be opening holes that go into the engine so before you begin get a can of compressed air (yellow arrow) and blow all the dust and debris away from the injector ports (red arrows).

Open the gas cap (red arrow) to relieve any residual pressure.
Figure 2

Open the gas cap (red arrow) to relieve any residual pressure.

Disconnect the four wiring harnesses from each injector by squeezing in the two clips (red arrows) on the harness and pulling straight up.
Figure 3

Disconnect the four wiring harnesses from each injector by squeezing in the two clips (red arrows) on the harness and pulling straight up.

Lay the connectors (red arrows) on the top of the engine and unclip the plastic wiring tray (yellow arrows) from the fuel rail.
Figure 4

Lay the connectors (red arrows) on the top of the engine and unclip the plastic wiring tray (yellow arrows) from the fuel rail.

There are two fuel lines connected to the rail; the supply line (yellow arrow) and the return line (red arrow).
Figure 5

There are two fuel lines connected to the rail; the supply line (yellow arrow) and the return line (red arrow). Label and disconnect the lines. Be prepared to catch the small amount of fuel that will spill from them.

Disconnect the small hose (yellow arrow) from the fuel pressure regulator (red arrow) at the end of the fuel rail.
Figure 6

Disconnect the small hose (yellow arrow) from the fuel pressure regulator (red arrow) at the end of the fuel rail.

Remove the two 5mm Allen bolts (red arrow) holding the fuel rail to its mount.
Figure 7

Remove the two 5mm Allen bolts (red arrow) holding the fuel rail to its mount.

With everything removed pull the injectors (yellow arrows) from their ports (red arrows).
Figure 8

With everything removed pull the injectors (yellow arrows) from their ports (red arrows). They pull straight out on the angle they are inserted in. There are only held in by friction at this point and you will feel them "pop" when they release.

Set the injectors (red arrows) and wiring harness on the top of the engine.
Figure 9

Set the injectors (red arrows) and wiring harness on the top of the engine.

Be sure to put a few rags in the open holes in the manifold to prevent anything from falling into the engine (yellow arrows).
Figure 10

Be sure to put a few rags in the open holes in the manifold to prevent anything from falling into the engine (yellow arrows). If you drop something into this hole you must get it out before going any further, this hole goes directly into the cylinder head and will cause catastrophic damage if left in!

The injectors are held on by metal clips; they can be pried or pulled off the rail (red arrow).
Figure 11

The injectors are held on by metal clips; they can be pried or pulled off the rail (red arrow).

Next, you can remove the injector from the rail by wiggling it out, it is just held in by the O-ring at this point (red arrow).
Figure 12

Next, you can remove the injector from the rail by wiggling it out, it is just held in by the O-ring at this point (red arrow).

Figure 13

New injectors come complete with new O-rings. Apply a small amount of White Lithium grease (red arrow) and reinstall.

Bookmark and Share
Comments and Suggestions:
salah Comments: i am using a car model 1988 1.8L electic fule injector i need anew one gould you plz help me geeting it
November 25, 2014
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799. They can help you find the right part.
- Nick at Pelican Parts
 

  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: Sat 12/3/2016 02:35:39 AM