Injectors Replacing

Replacing The Injector(s)

Removal

Draining the fuel injection system
- Drain the fuel injection system.

Disconnect the quick release connector for the fuel line







- Wipe off any spilled fuel.
- Release the fuel line from the clamps.
- Press the clips together. Pull out the fuel line.

Removing the cover and the connectors







- Disconnect the injector(s) connectors.
- Turbocharged engines: remove the cable harness and its clips from the bracket.

Removing hoses and screws







- Remove the screws holding the fuel rail. Lift out the fuel distributor with the injectors still secured in place.
- Disconnect the vacuum hose from the manifold.

NOTE:
- Handle the injectors carefully so that they are not damaged.
- Retain all the rubber bushings for the intake manifold.

Removing the locking plate for the injectors







- Remove the three screws from the locking plate.
- Slacken off the fixing tool holding the injectors.
- Pull out the locking plate.

Turbocharged engines: note the position of the bracket.

Removing the injector(s)

Remove:







- the injector(s): Turn them so that they come out of the fuel rail.

Clean the outside.

Installation

Installing the injector(s)







- Replace the O-rings.
- Lubricate the O-rings with petroleum jelly.
- Install the injectors in the fuel rail.

Installing the locking plate for the injectors
- Press the locking plate into the lower securing position for the injectors.
- Position the locking plate.
- Turbocharged engines: position the bracket.







- Install the three screws. Tighten the screws to 10 Nm.
- Check that they are properly positioned (see the illustration).

Install the fuel rail with the injectors on the engine

NOTE: Use new O-rings. Lubricate the O-rings with petroleum jelly.

- Clean the intake manifold.
- Connect the vacuum hose to the manifold.
- Install the fuel rail on the intake manifold.
- Apply locking fluid (P/N 116 1053) on the screws.







- Tighten the screws to 10 Nm.
- Connect the injector(s) connectors. Check that all connectors have a rubber seal. Secure the cables in their holders.
- Turbocharged engines: secure the cable harness with the cable clips in the bracket.
- Secure the fuel line. Use a new retaining clip. Check that the fuel line is securely in place by pulling it.
- Reconnect all hoses.
- Check that it is properly sealed. Check the function.
- Install the throttle body cover.

Remove the pump trolley
Remove the pump trolley, see Draining the fuel injection system.