Fuel Injector: Service and Repair

Special tools: 999 5533 (5)

Draining Fuel System
- Drain fuel system.

Removing
Remove:
- Fuel rail cover.
- Injector connectors.
- Fuel line clips.





Installing holders
Install:
- Holders 999 5533 on injectors
- Press in the holders so that they are in good contact with injectors.
- Screw down adjustment screw so that the contact plate is in contact with the fuel rail, turn the screw another half turn.





Removing Fuel Rail
Remove:
- Screws holding fuel rail. Lift fuel rail with injectors.
- Remove fuel rail from fuel line by twisting it approx. 90° and pulling it away from the fuel line. Place paper under the connector to soak up fuel spillage.

NOTE: Handle injectors carefully to avoid damage to nozzles and needles.





Removing Injector Nozzles
Remove:
- Holder from injector nozzle to be replaced.
- Screws holding mounting rail to fuel rail.
- mounting rail.
- Injector nozzle to be replaced.





Installing Injector Nozzles
- Install the new injector nozzle. Lubricate injector nozzle O-ring with petroleum jelly.
- Remove all holders from injectors.
- Locate mounting rail. The injector nozzles must be pulled away from the fuel rail a few millimeters to install the mounting rail.
- Install mounting rail to fuel rail.

Installing
Install:
- All rubber damping elements on intake manifold.
- Fuel rail on intake manifold.
- New screws and tighten (tightening torque 10 Nm).
- Fuel line clips.
- Remove tools holding injectors.
- Injector connectors. Check that each connector is fitted with rubber seal.
- Covers over fuel rail and throttle pulley.