Removal and Replacement

Replacing the injector(s)

Removal

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

Note! 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 Draining The Fuel Injection System.