Fuel Rail and Fuel Injectors

GENERAL INFORMATION

Warning: Refer to the precautions in sub-section 6.3.2 before starting work.

If you believe an injector has failed, try cleaning it with a suitable injector cleaner, such as Holts Redex Injector Treatment.

"PHASE I" MODELS. Refer to subsection 6.3.2.11.1.

Note that additional gaskets are installed between the injectors and the retaining plates.

"PHASE II" MODELS. Removal

PROCEDURE

1. Remove the upper intake manifold section, following the instructions in steps 20–25 of subsection 6.3.2.13.

2. Disconnect the vacuum hose from the fuel pressure regulator.

3. Relieve the fuel system pressure. Refer to subsection 6.3.2.

6. Then, release the retaining clips and disconnect the fuel supply hose and the fuel return hose from the left side of the fuel rail (indicated by arrows (engines with 1.6 L displacement)).

4. Release the retaining clips and disconnect the connectors from the four injectors.

5. Remove the fuel rail mounting bolts, then carefully remove the fuel rail and injectors from the intake manifold and lift it out of the engine compartment.

6. Remove the gaskets installed between the fuel rail and the intake manifold, and remove the injector seals from the intake manifold.

7. Remove the two mounting screws and remove the retaining plate and gasket from the corresponding injector, noting how it was installed.

8. Press out the injector and remove the O-rings. Remove the remaining injectors in the same way.

9. Discard the seals and O-rings; new ones must be used during installation.

Installation

PROCEDURE

1. Installation is the reverse of removal. Pay attention to the following points during installation.

2. Before installing the injectors, install new O-rings on them (indicated by arrows).

3. Lubricate the O-rings with engine oil to ease installation, then install the injectors into the fuel rail. Make sure the gaskets are installed correctly, then install the retaining plates and tighten the mounting screws.

4. Install new injector seals into the intake manifold, and install the gaskets between the fuel rail and the intake manifold. Install the fuel rail onto the intake manifold and install the mounting bolts.

5. In a diagonal sequence, starting from the center, tighten the mounting bolts to the specified torque, Stage

1. Then, again in the same sequence, tighten the bolts to the specified torque, Stage 2.

6. Install the upper intake manifold section, following the instructions in subsection 6.3.2.13.

7. Make sure all hoses are connected correctly and, if necessary, secure them with clamps.

8. Adjust the accelerator cable, following the instructions in subsection 6.3.2.3.

9. When installation is complete, start the engine and check for fuel leaks.