Fuel Injector: Service and Repair

Fuel injection supply manifold

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Removing components
Remove the air cleaner (ACL) module. See: Fuel system pressure release, B5254T7 Fuel System Pressure Release.
Drain the fuel system. Service and Repair
Remove the hose clamp for the rubber hose on the throttle body (TB). Move the hose to one side.
Disconnect the throttle body (TB) connector.

Removal

Removing upper intake manifold




Remove the 6 screws for the upper section of the intake manifold. Move the manifold to one side.

Removing the fuel rail





Caution! Clean up any fuel spills using paper

Disconnect the connector for the fuel pressure sensor and the connector for the injectors. Remove the 2 fuel rail mounting screws.
Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold. Gently work the fuel rail and injector nozzles loose. Disconnect the fuel line to the fuel rail. Press in the two blue clips on the fuel rail. Pull the fuel line out of the fuel rail.

Removing injectors

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

Installation

Note! For tightening torques, see Specifications. Tightening Torque.

Installing injectors




Lubricate the injector O-ring using a thin layer of petroleum jelly. Install the new injector.

Installing the mounting rail




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. See: Tightening torque, B5254T7 Tightening Torque.

Vehicles with fuel rail bracket




Transfer the bracket to the new fuel rail.

Installing the fuel rail




Lubricate the injector O-rings using petroleum jelly. Depress the fuel rail. Ensure that all injectors sit correctly.
Press the quick-release connector together until a clicking sound is heard. Screw the fuel rail into place. Tighten. See: Tightening torque, B5254T7 Tightening Torque. Connect the connector for the injectors and the fuel pressure sensor.

Installing upper intake manifold





Install:
- new gaskets for the intake manifold
- the intake manifold. Align the guides with the lower section of the intake manifold
- the screws for the intake manifold. Tighten. See: Tightening torque, B5254T7 Tightening Torque
- the hose for the throttle body (TB). Tighten hose clamp.

Finishing

Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module. Service and Repair

Checks
Start the engine. Check the function of the engine. Check for leakage.