Fuel Injector: Service and Repair

Service repair no - 19.60.04 - Fuel Rail
Service repair no - 19.60.12 - Injectors

Remove
1. Remove upper inlet manifold gasket.
2. Release HT leads from clips on rocker covers and from spark plugs.







3. Disconnect multiplugs from coils.
4. Remove 2 lower coil fixing bolts and remove coil assembly.
5. Position absorbent cloth beneath fuel pipe to catch spillage.







6. Disconnect fuel feed hose from fuel rail


CAUTION: Plug the connections.


7. Release injector harness clips from fuel rail and disconnect injector multiplugs.







8. Remove 4 bolts securing fuel rail to inlet manifold.
9. Release injectors from inlet manifold and remove fuel rail and injectors.
10. Release spring clips securing injectors to fuel rail and remove fuel injectors.
11. Remove and discard 2 'O' rings from each injector.
12. Fit protective caps to each end of injectors.

Refit
13. Clean injectors and recesses in fuel rail and inlet manifold.
14. Lubricate new 'O' rings with silicone grease and fit to each end of injectors.
15. Fit injectors to fuel rail.
16. Secure injectors to fuel rail with spring clips.
17. Position fuel rail assembly and push-fit each injector into inlet manifold.
18. Fit bolts securing fuel rail to inlet manifold and tighten to 9 Nm (6 labor. ft).
19. Connect fuel feed hose to fuel rail.
20. Connect injector harness multiplugs and secure to fuel rail.
21. Carefully position coil assembly, fit 2 lower fixing bolts but do not tighten at this stage.
22. Connect multiplugs to coils.
23. Fit HT leads to spark plugs and clips on rocker covers.
24. Fit upper inlet manifold gasket.