Volkswagen Cars 2000-05

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation





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Fig. Remove the ignition wire holder to gain access to the fuel rail on 2.0L 8 valve engines



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Fig. Hex keys are needed to remove the fuel rail retaining bolts



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Fig. Note the position and length of each fuel rail retaining bolt



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Fig. Lift the fuel rail away from the injectors

  1. Remove the negative battery cable.
  2.  
  3. On 2.0L engines, remove the upper intake manifold to gain access to the fuel rail.
  4.  
  5. Detach the injector wiring harness connectors.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Detach the vacuum hose from the pressure regulator.
  10.  
  11. Loosen the clamps and remove the fuel supply hose.
  12.  
  13. Detach the fuel return hose.
  14.  
  15. Remove the fuel rail retaining bolts.
  16.  
  17. Remove the fuel rail and the injectors as an assembly away from the intake manifold.
  18.  

To install:

  1. The procedure for the installation of the fuel rail and the injectors is the reverse of the removal procedure.
  2.  


NOTE
Always replace the fuel injector O-rings with new ones every time the injectors have been removed. Check that all vacuum hoses and electrical connections have been made. Always check for fuel leaks immediately after the engine has been started.

  1. Tighten the fuel rail bolts to 84 inch lbs. (10 Nm) on 2.0L engines.
  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine appearance cover, if equipped
     
    Engine under cover, if equipped
     
    Air cleaner and ducting
     
    All necessary vacuum and electrical connectors that interfere with fuel rail removal
     
    Fuel pressure and return lines
     
    Fuel injector connectors
     
    Fuel supply rail with injectors attached
     
    Fuel injectors from the supply rail

    Click image to see an enlarged view

    Fig. Fuel injectors and fuel rail-1.8L Golf, GTI and Jetta shown: other models similar



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    Fig. Fuel injectors and fuel rail-2.8L Golf, GTI and Jetta shown: other models similar

     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors to the fuel supply rail using new O-rings
     
    Fuel supply rail with injectors attached. Tighten the bolts to 89 inch lbs. (10 Nm)
     
    Fuel injector connectors
     
    Fuel pressure and return lines
     
    All necessary vacuum and electrical connectors
     
    Air cleaner and ducting
     
    Negative battery cable
     
    Engine appearance cover, if equipped
     
    Engine under cover, if equipped
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

 
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