Date:         Thu, 13 May 2004 08:02:59 EDT
Reply-To:     THX0001@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         George Goff <THX0001@AOL.COM>
Subject:      Re: Fuel injector electrical terminal rubber grommet replacement
Comments: To: Pascal.Giasson@GNB.CA
Content-Type: text/plain; charset="US-ASCII"

In a message dated 5/12/04 9:27:44 PM, Pascal.Giasson@GNB.CA writes:

<< Does anyone have any idea how to replace the rubber grommet that seals the
fuel injector electrical terminal? >>

Pascal,

There are two parts which protect each fuel injector connector from the
elements, neither of which I would call a grommet.  There is an annular, square
cross-section seal which is placed into a groove in the open end of the connector
body and there is a boot which seals the conductors to the connector body.

Obviously, the annular seal is just picked out and replaced.  Before the boot
can be replaced, the conductors must be removed from the body of the
connector.  The terminals are released from the body of the connector by inserting a
suitable probe into the terminal cavity to release the terminal retaining barb
from its seat.  Looking into the open end of the connector you will see
keyways in the connector body at each terminal into which you can insert the probe.
There are tools for this purpose, but a substitute is improvised easily
enough.

I have never replaced a boot without installing new terminals so I cannot say
how easily an attached terminal will fit through the conductor hole in the
boot.  But, soap it up with some lubricant (cable pulling lube, caliper assembly
lube, Murphy's Oil Soap, etc.) and go at it.

Other remedies:

Seal the open end of the connector body with Scotchfil. butyl glazing tape or
even body dum-dum.

Install replacement connectors from VW or the connectors shown at the
following address might work:

http://store.summitracing.com/partdetail.asp?part=MSD%2D2400

George