Fuel Injector: Service and Repair

WARNING: Since replacement of the injectors entails working on the car's fuel system, the following points should be observed in connection with installation
- Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapors is available, be sure to use it.
- Wear protective gloves. Prolonged contact with fuel can cause skin irritation or dermatitis.
- Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads, etc. in electrical circuits.
- No smoking anywhere in the vicinity.

To Remove

IMPORTANT: Scrupulous cleanliness must be observed when carrying out any work on the fuel rail and injectors. Thoroughly wash the area round the injectors, fuel rail and intake manifold and blow dry with compressed air.

1. Remove the engine covers.
2. Remove the rubber hose section. Remove cable conduits and the intake manifold mounting bracket.
3. Disconnect the throttle and cruise control cables from the throttle lever and bracket. Detach the brake servo and crankcase ventilation vacuum hoses.





4. Remove the 7 nuts securing the upper half of the intake manifold.
5. Lift up the upper half of the intake manifold and support it with a rubber mallet or the like.

Plug the intake pipes with paper or rags to prevent screws and the like from falling into the cylinders.





6. Unplug the connectors from all injectors.
7. Unscrew the fuel rail retaining bolts.

Use a screwdriver to work the fuel rail loose.

8. Remove the retaining clip for the injector or injectors that are to be checked and/or replaced.

Cover the injector with a cloth to catch any fuel that drips out and then with draw the injector from the fuel rail.





To Install
1. Inspect the O-rings at both ends of the injector. Coat them with a little petroleum jelly (Vaseline) to facilitate refitting.
2. Install the injector or injectors on the fuel rail and refit the retaining clip.
3. Install the fuel rail in place and tighten it.
4. Plug in the injector connectors.
5. If necessary, clean the intake manifold mating surfaces. Remove the paper or rags plugging the intake pipes and install a new gasket.

Correctly position the upper half of the intake manifold.





6. Tighten all the intake manifold retaining nuts. Start by tightening the nuts in the middle and continue alternately to the outermost nuts.

Tightening torque: 20 Nm (15 ft lbs).

7. Tighten the mounting bracket at the rear of the intake manifold.

Install the cable conduits.

8. Check that the pressure regulator's vacuum hose is fitted on the throttle body's front connector (in front of the throttle valve).
9. Reconnect the crankcase ventilation and brake servo vacuum hoses and install the throttle and cruise control cables to the throttle lever and mounting bracket.
10. Install the rubber hose section and tighten the hose clips. Reconnect the IAC hose.
11. Install the covers on the engine.