Fuel Injector: Service and Repair

Fuel Injector Replacement

Special Tools
* J 34730-1A /KM-J-34730-91 Fuel Pressure Gage
* KM-807 Closure Plugs
* J 37088-A Fuel Line Disconnect Tool Set

Removal Procedure

1. Open the hood.
Warning: Refer to Battery Disconnect Warning (Service Precautions).

2. Disconnect the battery.

* Remove the ground connection from the negative terminal.
* Loosen the nut.




3. Remove the engine venting pipe (1).

* Remove the wiring (2) from the cylinder head cover.
* Disconnect the 2 quick-release fittings.

4. Remove the engine management wiring harness.

* Disconnect the 9 wiring harness plugs.

- Engine control module
- Air mass flow meter
- Tank vent valve
- Throttle valve module
- Valve, intake camshaft adjustment
- Four injector valves

* Remove the 2 wiring harness brackets.
* Put the wiring harness to the side.

5. Place a drain pan underneath.
Warning: Refer to Gasoline/Gasoline Vapors Warning (Service Precautions).

6. Release the fuel pressure via the test connection (1) using J 34730-1A /KM-J-34730-91.
Collect the exiting fuel in a suitable container.




7. Remove the fuel return line (1).

* Remove the quick-release fitting with J 37088-A .
* Seal the fuel line and the fuel rail with KM-807 .




8. Remove the fuel rail (2).
Remove the 2 bolts (1).




9. Remove the injectors.

* Remove the 4 retaining clamps (1).
* Pull out the 4 injectors.

Installation Procedure

Note: Inspect the installation position and ensure correct fitting.

1. Install the 4 injectors to the fuel rail.

* Install the 4 new seal rings.
* Coat the seal ring with silicone grease (white).
* Install the 4 injection valves.
* Install the 4 retaining clamps.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the fuel rail.

Tighten the 2 bolts to 8 Nm (71 lb in).

3. Install the fuel supply line to the fuel rail.

* Remove the 2 KM-807 .
* Connect the quick release fitting.
* Connect into the bracket.

4. Install the engine management wiring harness.

* Connect the 9 wiring harness plugs.

- Engine control unit
- Air mass flow meter
- Tank vent valve
- Throttle valve module
- Intake camshaft actuator
- Four injectors

* Install the 2 wiring harness brackets.

5. Install the engine vent hose.

* Connect the 2 quick-release fittings.
* Connect the wiring harness to the cylinder head.

6. Connect the battery.
Install the ground connection to the negative terminal.

Tighten the ground connection nut to 5 Nm (44 lb in).

7. For programming procedures, refer to Control Module References (Programming and Relearning).
8. Close the hood.