Injectors/Pulsation Dampers, Replacing

Injectors/Pulsation Dampers, Replacing

NOTE: As 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.

Removal

Removing upper intake manifold
Drain the fuel system.
Remove the air cleaner (ACL) module.

CAUTION: Seal the openings in the lower part of the intake manifold. Use tape or similar.







Remove/slacken off the hose clamp for the hose between the intake manifold and the mass air flow (MAF) sensor.

Remove/slacken off the 6 screws for the upper intake manifold closest to the front cover plate. Remove/slacken off the 2 screws against the firewall.

Lift up the intake manifold. Bend the intake manifold to one side. Place the intake manifold on the battery box.

Draining the fuel system
Disconnect the connector for the injectors and the fuel pressure sensor in the fuel rail.

Removing the injectors







Blow clean around the injectors.
Remove the mounting screws from the fuel rail. Spray universal oil or similar around the injector terminals on the intake manifold.

Pull out the fuel rail and injectors. Do not work them loose from side to side. Separate the fuel line quick-release connector. Press the 2 blue plastic buttons.

Lift out 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.

Installing injectors
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 fuel rail







Press the fuel rail down. Ensure that all injectors locate correctly.
Press the quick-release connector together until clicking sound is heard. Screw the fuel rail into place.
Connect all the connectors to the injectors and to the fuel pressure sensor.

CAUTION: Ensure that the guides for the lower section are in the correct position.

Install:







- new gaskets for the upper section of the intake manifold
- the upper intake manifold.

Tighten the screws alternately. Tighten the intake manifold screws.

Tighten the hose clamp to the mass air flow (MAF) sensor. Connect the connector to the pressure sensor on the intake manifold. Install a new tie strap for the cable harness.

Finishing

Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module.

Checking injectors
Start the engine. Check the function of the engine. Check for leakage.