Fuel Injector: Service and Repair

Fuel Injection System Components, Removing and Installing.







NOTE: Prior to removing the fuel injectors, the intake manifold must first be removed.


1 - 25 Nm.

2 - Intake Manifold Upper Section.
- Disassembling and Assembling, refer to: Vehicle /Engine, Cooling, and Exhaust /Engine /Intake Manifold/ Service and Repair.
Intake Manifold Upper Section, Disassmbling and Assembling
- Removing and Installing, refer to: Vehicle /Engine, Cooling, and Exhaust /Engine / Cylinder Head Assembly/ Valve Cover/ Service and Repair.
Service and Repair

3 - Vacuum Connection.
- From Leak Detection Pump (LDP) - V144 -.
- EVAP System.

4 - 81-pin Harness Connector.
- Only disconnect or connect with ignition switched off.
- Release to disconnect.







5 - Motronic Engine Control Module (ECM) - J220 -.
- Located in plenum chamber.
- Check voltage supply

6 - 10 Nm.

7 - Retaining Frame.

8 - 40-pin Harness Connector.
- Only disconnect or connect with ignition switched off.
- Release to disconnect.

9 - From Brake Booster.

10 - From Evaporative Emissions (EVAP) Canister Purge Regulator Valve - N80 -.
- EVAP system.







11 - 3-Pin Harness Connector.
- White.
- For Knock Sensor (KS) 1 - G61 -.
- Sensor and harness connector contacts are gold plated.

12 - Supply Connection.

13 - Return Flow Connection.

14 - Intake Manifold Lower Section.
- Disassembling and assembling, refer to: Vehicle /Engine, Cooling, and Exhaust /Engine /Intake Manifold/ Service and Repair.
Intake Manifold Lower Section, Disassembling and Assembling

15 - Seal.
- Always replace.

16 - Bracket.
- For Secondary Air Injection (AIR) pump motor - V101 - and secondary air inlet valve.
- Secondary air system.







17 - Wiring Harness.
- With harness connectors for fuel injectors.

18 - 5-Pin Harness Connector.
- Black.
- For Mass Air Flow (MAF) sensor - G70 - with Intake Air Temperature (IAT) sensor - G42 -.
- Sensor and harness connector contacts are gold plated.

19 - 6 Nm ( 53 in. lb ).

20 - Retaining Clip.

21 - O-ring.
- Replace if damaged.

22 - Thermostat Housing.







23 - Engine Coolant Temperature (ECT) sensor - G62 -.
- Blue.
- For Engine Control Module (ECM).
- With Engine Coolant Temperature (ECT) sensor - G2 -..
- If necessary, release pressure in cooling system before removing.
- Check.
- Connector terminals -1- and -3- for Engine Coolant Temperature (ECT) sensor - G62 -.
- Terminals - 1 - and -3- are gold plated.

24 - Air Cleaner.

25 - Engine Speed (RPM) Sensor - G28 -.
- Check.

26 - O-ring.
- Always replace.







27 - 4-Pin Harness Connector.
- Black.
- For oxygen sensor behind Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) Heater 1 - Z29 -.
- Located at right on underside of vehicle.
- Terminals 3 and 4 plated.

28 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130 -.
- 50 Nm.
- Location: in rear of Three Way Catalytic Converter (TWC).
- Grease only threads with G 052 112 A3 hot bolt past (anti-seize compound). Grease must not get into slots on sensor body.
- Remove and install using 3337.
- Oxygen sensor heater voltage supply via Fuel Pump (FP) relay - J17 -.
- Check.







29 - 6-pin Harness Connector.
- Black.
- For Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater - Z19 -.
- Located at right on underside of vehicle.







30 - Heated Oxygen Sensor (HO2S) - G39 -.
- 50 Nm.
- Location: in front of Three Way Catalytic Converter (TWC).
- Grease only threads with G 052 112 A3 hot bolt paste (anti-seize compound). Grease must not get into slots on sensor body.
- Remove and install using special tool 3337.
- Oxygen sensor heater voltage supply via Fuel Pump (FP) relay J17.
- Check.

31 - Intake Hose.
- Make sure it is seated securely.
- Press together at front to release.
- To Secondary Air Injection (AIR) pump motor - V101 -.







32 - Connecting Hose.
- For crankcase breather.
- From breather housing on cylinder head cover.

33 - 2-pin Harness Connector.
- Black.
- For Positive Crankcase Ventilation (PVC) heating element -N79-.
- Check heater element voltage supply between terminal - 1 - and -2- with engine running: Specified value: at least 11.5V.

34 - Bracket.
- Secured to front of oil pan.

35 - Vacuum Reservoir.
- For intake manifold change-over.

36 - From Secondary Air Injection (AIR) Solenoid Valve - N112 -.
- Secondary air system.







37 - Non - Return Valve.
- Black valve side faces T-pieces connection fuel pressure regulator / intake manifold upper section.

38 - 2-Pin Harness Connector.
- Black.
- For Secondary Air Injection (AIR) solenoid valve - N112 -.

39 - Secondary Air Injection (AIR) Solenoid Valve - N112 -.
- Secondary air system.

40 - Intake Manifold Change - Over Valve - N156 -.
- Check.

41 - 2-Pin Harness Connector.
- Black.
- Intake Manifold change-over valve - N156 -.