Fuel Injector: Service and Repair

INJECTOR REPLACEMENT





Release of Fuel System Pressure
^ Drain fuel system pressure. See: SYSTEM DIAGNOSIS / DRAINAGE OF FUEL SYSTEM.

Injector Removal
^ Remove:
- Upper charge-air pipe.
- Fuel rail cover.
- Injector connectors.
- Fuel line clips.





Installation of clamps
^ Mount clamps P/N 9995533 on injectors.
^ Press in clamp to ensure that it is seated firmly against injector.
^ Screw down adjusting screw until clamping piece is in contact with fuel rail and tighten another half turn.





Removal of Fuel Rail
^ Remove / Disconnect:
- Vacuum hose from pressure regulator.
- Fuel rail retaining bolts.
- Lift off rail complete with injectors.
- Remove clamp from injector to be replaced.

NOTE: Handle injectors carefully to avoid damage to injection nozzles and needles.

NOTE: Recover all rubber damping elements mounted on intake manifold.





^ Place rag under injector to soak up fuel spillage.
^ Ensure that spacer is located in fuel rail 0-ring seat.
^ Replace injector. Lubricate 0-ring of new component with petroleum jelly.





Injector Installation
^ Install / Reconnect:
- All rubber damping elements on intake manifold.
- Fuel rail on intake manifold.
- Fuel rail retaining bolts.

Use new bolts and tighten to 10 Nm (7.5 ft lb.).

- Fuel line clips.
- Remove injector clamps.
- Injector connectors. Check that each connector is fitted with rubber seal.
- Covers over fuel rail and throttle pulley.
- Upper charge-air pipe.