Orlando

Fuel Injector Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Open the bonnet.
2. Disconnect the negative cable from the battery. Refer to  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 .
4. Disconnect the wiring harness from the:

4.1.	Evaporative emission purge valve

4.2.	Fuel injectors

5. Place a collecting basin underneath.

Warning: Petrol or petrol vapours are highly flammable. A fire could occur if an ignition source is present. Never drain or store petrol 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 EN-34730-91 gauge .



7. Disconnect the quick-release fitting of the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
8. Install and close the fuel feed pipe with CH-807 plug .



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.

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 in the Preface section.

5. Install the 2 multiport fuel injection fuel rail bolts (3) and tighten to 8 N·m (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 N·m (71 lb in).



8. Remove the CH-807 plug .
9. Connect the quick-release fitting of the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
10. Connect the wiring harness to the:

10.1.

Evaporative emission purge valve

10.2.

Fuel injectors

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 .
12. Connect the negative cable to the battery. Refer to  Battery Negative Cable Disconnection and Connection : without Start/Stop System .
13. Close the bonnet.