Fuel Injector: Service and Repair

Removal
1. Relieve fuel pressure according to "Fuel Pressure Relief Procedure".
2. Disconnect battery negative cable at battery.




3. For G16 (1.6L) engine, detach intake manifold stiffener (front) (1) from intake manifold.
4. For J20 (2.0L) engine, remove PCV hose and breather hose.




5. Disconnect coupler (1) from each injector.




6. Remove clamp bolt (1) for fuel feed pipe and return pipe.
7. Remove fuel delivery pipe bolts.




8. Remove fuel injector(s) (1) from delivery pipe (2) and intake manifold or cylinder head.

WARNING: A small amount of fuel may be released when fuel injector is removed. In order to reduce the chance of personal injury, cover them with a shop cloth.




Installation
1. Replace injector O-ring (3) with new one using care not to damage it. Install grommet (2) to injector.
2. Check if insulator (1) is scored or damaged. If it is, replace with new one. Install insulators (1) and cushions (4) to intake manifold or cylinder head.
3. Apply thin coat of fuel to O-rings (1) and then install injectors into delivery pipe and intake manifold or cylinder head. Make sure that injectors rotate smoothly. If not, probable cause is incorrect installation of O-ring.
Replace O-ring with new one.




4. Tighten delivery pipe bolts and make sure that injectors rotate smoothly.

Tightening torque
Fuel delivery pipe bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

5. Connect couplers to injectors securely.
6. For G16 (1.6L) engine, install intake manifold stiffener (front) to intake manifold. For J20 (2.0L) engine, install PCV hose and breather hose and clamp then securely.
7. Install clamp bolts for fuel feed pipe and return pipe.
8. Connect battery negative cable.
9. With engine "OFF" and ignition switch "ON", check for fuel leaks around fuel line connection.