Volkswagen Golf/Jetta/Cabriole 1990-1999

Fuel Injector(s)

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REMOVAL & INSTALLATION





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Fig. Inner view of a mechanical fuel injector



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Fig. Pull the fuel injector wiring harness from the injector



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Fig. Observe the location of the injector wiring harness spring clips



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Fig. Close up of injector wiring harness



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Fig. Notice the arch in the injector wiring harness connector. It will only slide over the injector in one direction

  1. Relieve the fuel system pressure.
  2.  
  3. On CIS-E Motronic systems pull the injectors straight out of the intake manifold using a tool designed specifically for the job. Fuel injector removal tools are sold at most automotive suppliers or at your local VW dealer.
  4.  


NOTE
Use a spray lubricant to ease the removal of any stuck injectors.

  1. Now hold the fitting with a line wrench and unscrew the injector.
  2.  


NOTE
If it is difficult to remove the injectors from their lines, use a penetrant to aid in the process.

  1. The injectors can now be removed from the lines if desired.
  2.  

To install:

  1. Install the fuel injectors on the lines.
  2.  
  3. Lubricate the injector O-rings with a spray lubricant or gasoline.
  4.  
  5. Install the injectors.
  6.  

TESTING





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Fig. To test the injectors probe the two prongs at the rear of each injector with the leads of a multimeter . . .



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Fig. . . . set the meter to the ohms scale and check the resistance of each injector. A shorted injector will show zero ohms

  1. Unplug the connector at the end of the fuel rail.
  2.  
  3. Connect a Digital Volt Ohm Meter (DVOM) to the terminals and measure the resistance
  4.  
  5. If the resistance is high, remove the wiring from each injector and recheck each individually.
  6.  
  7. The resistance should be between 14-18 ohms.
  8.  
  9. If the injectors are not within specification, replace them with new ones.
  10.  

 
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