Fuel Injector Replacement - 5KCSTQ

["Lawson, Dave" <dlawson@ball.com>]

Mark,
>
I received new (used) injectors from VW Parts ($15 each).  The manual
says to pull the injectors and then disconnect from fuel line.  Seem
like there is a _great_ possibility of deforming/crimping the line
doing this.  Any BTDTs?  It is pretty tight in there!
>

I swapped my injectors this past weekend on my 1990 200 q wagon. 
Not real tough, but you don't want to mung anything up.

1) remove injector cooling fan air outlet, 4 screws

1a) liberally spray all injector connections with penetrating
oil

2) remove throttle cable/cruise control guide, 3 bolts on top
of intake manifold(10mm and 13mm), 2 clips for throttle cable, 
cir-clip for cruise rod ball/socket, undo injector line retaining
clip, set aside

3)pop out injectors, I use the L shaped tool designed for
this purpose

4)injector should now be loose in its hole, undo the fuel line
to the injector, 12mm and 14mm

5)push fuel line aside and remove injector, make sure air
shroud tip is on injector

6)install new o-ring(should be green) on replacement injector,
(believe it or not I slide them down over the threaded part, my 
hands still hurt) lube both upper and lower o-rings, I used 
some mobil 1

7)slide injector into mount hole

8)connect fuel line to injector

9)seat injector into its mounting

10)repeat steps 3-9 for the other 4 injectors

11)re-install throttle guide parts, be sure to connect ground wires

12) re-install injector cooling fan distribution shroud

I had to remove the TB hose to get room to use the removal tool
on #1, so I used this opportunity clean out the hose.

HTH
-
Dave Lawson
1990 200 q avant, undergoing preventative maint
1986 GT, for parts
1983 ur-q, randomly dripping ATF on garage floor to mark it's spot