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Pelican Technical Article:

Fuel Injector Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$50 to $200

Talent:

****

Tools:

5mm hex driver, silicone lubricant, fire extinguisher

Applicable Models:

Jetta MkIV 2.0L (1998-05)

Parts Required:

Fuel injector

Hot Tip:

Relieve pressure in the fuel rail beforehand

Performance Gain:

Better running engine

Complementary Modification:

Replace fuel filter

Is your car running sluggishly? Are you noticing a slight stumble as you drive? Chances are your fuel injectors need to be cleaned and/or replaced. In this tech article, I will go over the steps in removing the fuel injectors and cleaning them out. This article applies to the Mk4 Jetta, however the principles behind this apply to nearly every car in general. Usually, most people just run a can of fuel injector cleaner in a full tank of gas. I would also recommend this, but in cases of cars that have been poorly maintained or have been sitting for a while, the only way to get those injectors truly clean is to pull them out and have them ultrasonically cleaned by a professional.

One of the nice features of the Mk4 Jetta is the OBD2 system. This typically will throw a check engine light (CEL) in the event of an actual injector failure. Once you get a CEL, you'll want to use a code reader to extract the diagnostic trouble code (DTC) stored in the computer. Typically, this manifests as a P0201 thru P0204 code. For example, a P0204 code would indicate a problem with injector number 4.

Keep in mind that you will be working around raw fuel. It's a good idea to have a fire extinguisher nearby. Better safe than sorry. You'll also need to relieve the fuel pressure built up in the fuel rail, otherwise, you'll get a pressurized blast of fuel all over the place when you disconnect the feed line to the rail. This is done by removing the fuel pump fuse from the fuse box, and then run the car until the engine dies. This method has the advantage of using up all the fuel in the rail; however, it may trigger a DTC indicating a failure in the fuel pump circuit. If you start the car and the CEL comes on, the DTC stored in the computer will need to be read and then cleared from the computer.

Accessing the fuel injectors requires removing the intake manifold. Please see our article on Intake Manifold Removal for more information.

Begin by opening the fuse box and remove fuse number 28.
Figure 1

Begin by opening the fuse box and remove fuse number 28. This will disable the fuel pump. Start the car and let it run till it dies. This will relieve any residual fuel pressure in the fuel line and prevent you from getting sprayed with gasoline.

Press the tabs on the electrical connectors to each fuel injector (green arrows) and pull them off.
Figure 2

Press the tabs on the electrical connectors to each fuel injector (green arrows) and pull them off. Also carefully slide the plastic harness holder (purple arrow) and slide it to the right and off the fuel rail.

Access to the fuel injector electrical connections can be a little tricky.
Figure 3

Access to the fuel injector electrical connections can be a little tricky. You'll need to press hard on the release tabs while pulling. It's a bit difficult but you do have enough room.

Loosen and remove the two 5mm hex bolts (green arrows) securing the fuel rail to the engine.
Figure 4

Loosen and remove the two 5mm hex bolts (green arrows) securing the fuel rail to the engine.

Pull up on the fuel rail until the injector (green arrow) pops out of the mounting bore (purple arrow) Take note of the mounting bore.
Figure 5

Pull up on the fuel rail until the injector (green arrow) pops out of the mounting bore (purple arrow) Take note of the mounting bore. Sometimes an O-ring can be stuck inside. Also use a light coat of silicone lubricant on the O-ring when installing the injector. It makes it slightly easier to pop back in.

Pull the vacuum hose off the fuel injector.
Figure 6

Pull the vacuum hose off the fuel injector. This requires a good amount of force. I ended up tearing all of the hoses. Be sure to have some new vacuum hose ready. Use the old hose to measure length.

Turn the fuel rail over and you'll see the mounting clip (green arrow) that secures the injector to the fuel rail.
Figure 7

Turn the fuel rail over and you'll see the mounting clip (green arrow) that secures the injector to the fuel rail.

Carefully slide the mounting clip (green arrow) off.
Figure 8

Carefully slide the mounting clip (green arrow) off. Be careful as it is under tension and can go flying away very easily.

Now pull the injector (green arrow) out of the fuel rail (purple arrow).
Figure 9

Now pull the injector (green arrow) out of the fuel rail (purple arrow). Like before, lightly lubricate the O-ring with some silicone lubricant when installing the injector. The remainder of the job is the reverse of removal.


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Comments and Suggestions:
HR Comments: Beside holding injector in place, do clips hold another purpose? i.e conductor observer or a ground purpose?
I changed all injector to my vw jetta 2002 2.0 but didn't place clips. Could this be a reason why my misfired code is on? There is absolutely no shaking/stalling
June 27, 2016
  Followup from the Pelican Staff: The clips hold the rail tot he injector for safety and leak prevention. I do not think it would cause a misfire. - Nick at Pelican Parts  

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