Fuel Injector: Service and Repair
Fuel Injector Replacement
Special Tools
* CH-48027 - Fuel Pressure Gauge
* CH-41769 - Fuel Line Disconnect Tool Set
For equivalent regional tools, refer to Special Tools Tools and Equipment.
Removal Procedure
1. Open the hood.
2. Disconnect the negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (without Start/Stop System) Battery Negative Cable Disconnection and Connection (without Start/Stop System).
3. Remove the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (1.6L LDE, LXV, 1.8L 2H0, LUW and LFH) Service and Repair.
4. Disconnect the wiring harness from the:
1. Evaporative emission purge valve
2. Fuel injectors
3. Manifold absolute pressure sensor
5. Place a drain pan underneath the vehicle.
Warning
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
6. Release the fuel pressure using the test connection with CH-48027 - gauge.
7. Disconnect the quick-release fitting of the fuel feed pipe (1) with CH-41769 - tool set.
8. Install a suitable cap to the fuel feed pipe.
9. Remove the 2 evaporative emission canister purge solenoid valve bracket bolts (2).
10. Remove the evaporative emission canister purge solenoid valve bracket (1) from the intake manifold (7).
11. Remove the 2 multiport fuel injection fuel rail bolts (3).
12. Remove the multiport fuel injection fuel rail (4) with the fuel injectors (5) from the intake manifold (7).
13. Remove the 4 fuel injector seals (6).
14. Remove the fuel injector retainer (1).
15. Remove the fuel injectors.
Installation Procedure
1. Install the fuel injectors.
Note: Install NEW fuel injector seals, coat the multiport fuel injector seals with silicone grease.
2. Install the fuel injector retainer (1).
Note: Coat the fuel injector seals with silicone grease.
3. Install the 4 NEW fuel injector seals (6).
4. Install the multiport fuel injection fuel rail (4) and the fuel injectors (5) to the intake manifold (7).
Caution: Refer to Fastener Caution Fastener Caution.
5. Install the 2 multiport fuel injection fuel rail bolts (3) and tighten to 8 Nm (71 lb in).
6. Install the evaporative emission canister purge solenoid valve bracket (1) to the intake manifold (7).
7. Install the 2 evaporative emission canister purge solenoid valve bracket bolts (2) and tighten to 8 Nm (71 lb in).
8. Remove the cap from the fuel feed pipe (1).
9. Connect the quick-release fitting of fuel feed pipe (1).
10. Connect the wiring harness to the:
1. Evaporative emission purge valve
2. Fuel injectors
3. Manifold absolute pressure sensor
11. Install the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (1.6L LDE, LXV, 1.8L 2H0, LUW and LFH) Service and Repair.
12. Connect the negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (without Start/Stop System) Battery Negative Cable Disconnection and Connection (without Start/Stop System).
13. Close the hood.