Procedures

Replacing Injectors/Pulsation Dampers

Preparation







Drain the fuel system according to Draining the fuel system.
Remove the cover over the fuel rail.
Disconnect the injector connectors.
Blow clean around the injectors.
Remove the fuel rail mounting screws.
Separate the fuel line quick-release connector.
Spray universal oil or similar around the injector terminals on the intake manifold.
Pull out fuel rail and injectors loose. Do not work them loose from side to side.

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

Removing the injectors

Remove
- the screws holding the mounting rail to the fuel rail
- the mounting rail
- the injector

Removing the pulsation damper

Remove
- the screws holding the mounting rail to the fuel rail
- the mounting rail
- the pulsation damper.

Installing injectors
Lubricate the injector O-rings with a thin layer of petroleum jelly.
Install the new injector.

NOTE: A new injector must be used if the nozzle separates from the injector.

Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail.
Tighten the mounting rail to the fuel rail.

Installing the pulsation damper
Lubricate the new pulsation damper O-ring with a thin layer of petroleum jelly.
Install the new pulsation damper.
Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail.
Tighten the mounting rail to the fuel rail.

Finishing







Depress the fuel rail. Ensure that all injectors sit correctly.
Screw the fuel rail into place. Use new screws. Tighten to 10 Nm.
Press the quick-release connector together until a clicking sound is heard.
At the same time connect all the connectors to the injectors.
Reinstall the cover over the fuel rail.
Start the engine. Check for fuel leakage.