Removing and installing fuel injectors

Removal is described for the 1.6 L engine. Observe the notes for the 1.8 / 2.0 L engines at the end of this section.

• Remove upper intake manifold section, see section "Cylinder head removal", page 37.

• Unbolt 2 fuel rail bolts -arrows-.

• Unbolt lower intake manifold from cylinder head -

• Disconnect vacuum line from fuel pressure regulator.

• Warning: fire hazard, no smoking. The fuel system is under pressure. Catch escaping fuel with a rag. Unbolt fuel supply and fuel return lines from fuel rail.

• Pull fuel rail complete with injectors upward out of cylinder head.

• Pull retaining clips -8- off to the side and remove injectors -3-, similar to illustration T-2253 below.

• Lightly coat O-rings -1- with petroleum jelly or SAE 90 gear oil.

• Press fuel rail with injectors evenly into intake manifold and slide retaining clips on from the side.

• Attach fuel rail to intake manifold with 2 bolts, tightened only snug to 10 N·m.

• Connect fuel supply and fuel return lines to fuel rail.

• Connect vacuum line to fuel pressure regulator.

• Connect connectors to fuel injectors.

• Bolt intake manifold to cylinder head evenly with new gasket to 30 N·m.

• Install upper intake manifold section, see section "Cylinder head installation", page 37.

• The intake manifold does not need to be removed beforehand.

• Warning: fire hazard, no smoking. The fuel system is under pressure. Catch escaping fuel with a rag. Unbolt fuel supply -1- and fuel return -2- lines from fuel rail.

• Disconnect vacuum line -3- from fuel pressure regulator.

• Unbolt fuel rail with 2 bolts -arrows-.

• Pull fuel rail complete with injectors upward out of cylinder head.

• 1.8 L engines: pull injectors out of fuel rail.

  The injectors are only inserted and can be pulled out.

• 2.0 L engine: pull retaining clips -8- off to the side and remove injectors -3-. If necessary, remove fuel pressure regulator -2-; to do so, remove clip -9-.