Fuel Injector: Service and Repair
To Remove
IMPORTANT: Scrupulous cleanliness must be observed when carrying out any work on the fuel rail and injectors.
Thoroughly wash the area round the injectors, fuel rail and intake manifold and blow dry with compressed air before removing the components.
1. Remove the intake manifold and resonating chamber.
2. Uncover the throttle housing and remove the three hoses. Note the positions of the two thin hoses in relation to each other.
3. Uncover the cable conduit at the rear of the intake manifold and disconnect the brake servo vacuum hose.
4. Unplug the IAC valve connector and disconnect the hose. Remove the vacuum hose and electrical connector from the control valve for the variable intake manifold's inner flap.
5. Remove the four covers over the intake manifold bolts.
6. Remove the four intake retaining manifold bolts.
WARNING:
Since replacement of the injectors entails working on the car's fuel system, the following points should be observed in connection with installation:
Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapors is available, be sure to use it.
Wear protective gloves. Prolonged contact with fuel can cause skin irritation or dermatitis.
Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.
No smoking anywhere in the vicinity.
7. Remove the intake manifold. Plug the intake pipes with paper or rags so that nothing can fall into the cylinders.
8. Unplug the electrical connectors from the injectors.
9. Remove the cable conduit from the fuel rail.
10. Remove the screws securing the fuel rail.
11. Carefully lift up the fuel rail together with the injectors.
Be sure to have some absorbent paper or the like handy to soak up fuel which runs out of the fuel rail and injectors.
12. Remove the retaining clip securing the injector(s) that are to be changed/checked.
13. Inspect the O-rings and check their condition.
To Fit
1. Inspect the O-rings at both ends of the injector. Smear a little petroleum jelly (Vaseline) on them to facilitate refitting.
2. Fit the injector or injectors on the fuel rail and refit the retaining clip.
3. Fit the fuel rail in place and tighten it.
4. Plug in the injector connectors and refit the cable conduit.
5. If necessary, clean the mating surface of the intake manifold, inspect the sealing surfaces and check the condition of the O-rings. Lubricate the O-rings with a little petroleum jelly (Vaseline). Remove the
paper or rags from the intake pipes and refit the intake manifold.
Tightening torque: 20 Nm (14 ft lbs).
Refit the covers on the four retaining bolts.
6. Plug in the idle air control valve's electrical connector. Reconnect the IAC; valve's hose as well as the vacuum hose to the inner flap of the variable intake manifold. Plug the electrical connector into the control valve.
7. Fit the cable conduit to the rear of the intake manifold and the vacuum hose to the brake servo.
8. Check the sealing surfaces on the flaps and the condition of the O-rings. Lubricate the O-rings with a little Vaseline.
Fit the throttle and the three hoses.
Tightening torque: 8 Nm (6 ft lbs).
IMPORTANT: It is important to make sure that the two thinner hoses are connected to the right fitting. The hose from the T-pipe (vacuum tank and EVAP canister purge valve) should be connected to the outer fitting (nearest the left-hand wheel housing).
9. Fit the intake manifold and resonating chamber.
IMPORTANT: After refitting, it will be necessary to check and/or adjust the kickdown cable. This is done with special tool 87 92 459.