Fuel Injector: Service and Repair

Injector/pulse damper, replacement

Removal and Installation

Note! Since 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.

Preparation




Depressurize the fuel system according to: Fuel system pressure release Service and Repair.
Remove the charge air pipe over the engine. Seal the openings.





Note! Handle the injectors carefully to avoid damage to the fuel nozzles and fuel needles.

Remove the cover over the fuel rail.
Disconnect the injector connectors. Blow clean around the injectors.
Remove the mounting screws from the fuel rail.
Separate the fuel line quick-release connector. See: Fuel line, lock Service and Repair. Spray universal oil or similar around the injector terminals on the intake manifold.
Disconnect the connector for the fuel pressure sensor in the end of the fuel line. Gently work the fuel rail and injectors loose. Seal the openings.
Remove the tie strap for the fuel pressure sensor wiring.
Gently work the fuel rail and injectors loose. Seal the openings.

Removing injectors

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

Installing injectors

Note! For tightening torques, see: Tightening torque Tightening Torque




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

Finishing
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 Tightening Torque.
Lubricate the injector O-rings with petroleum jelly.




Depress the fuel rail. Ensure that all injectors sit correctly.
Screw the fuel rail into place. Use new screws and tighten. See Tightening torque Tightening Torque.
Connect the connectors for the injectors and the fuel pressure sensor.
Install a tie strap for the cable for the fuel pressure sensor.
Press the quick-release connector together until a clicking sound is heard. See Fuel line, lock Service and Repair.

Caution! The fuel pressure pipe must be in place.

Reinstall the cover over the fuel rail.




Remove the seals from the charge air pipe. Reinstall the charge air pipe over the engine.
Start the engine. Check for fuel leakage.