How to Replace a Fuel Injector in a VW Jetta

by Contributor

The VW Jetta mixes fuel and air under pressure with a fuel injector. This function was previously performed passively by carburetors until the late 1980s. One advantage of fuel injectors is the programmable firmware that allows the fuel injector to handle different fuels. A fuel injector includes only the nozzle and valve; it still requires the pump to pressurize the fuel.

Determine which fuel injector your VW Jetta will need. This depends not only on the make and model, but also the engine size. Models made from 1980 to 1984 have 1.6L or 1.7L engines. Models built from 1985 to 1990 had a 1.8L engine, and models made from 1991 to 1998 may be equipped with a 1.6L, 1.8L, 2.0L or 2.8L engine.

Look at recent models of the VW Jetta. Models manufactured from 1999 to 2004 have 1.4L, 1.6L, 1.8L, 2.0L or 2.8L engines. The current version debuted in 2005 and may have any of the following engines: 1.4L TSI, 1.6L FSI, 2.0L FSI, 2.0L TFSI or 2.5L.

Disconnect the negative battery cable and relieve the fuel system pressure with a socket wrench. Remove the engine appearance cover and engine under cover if present. Detach the air cleaner and air cleaner ducting.

Remove all vacuum hoses and electrical connectors that prevent you from accessing the fuel rail. Disconnect the fuel send and return lines and unplug the electrical connectors for the fuel injectors.

Detach the mounting bolts for the fuel rail with a socket wrench and lift the fuel rail out of the engine compartment with the fuel injectors still attached. You will then be able to pull the fuel injectors out of the fuel rail. Discard the old O-rings.

Install the new fuel injectors with new O-rings by reversing the removal procedure. Use a torque wrench to tighten the fuel rail mounting bolts to 89 inch pounds.

Start the engine and check for fuel leaks.

Items you will need

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