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Fuel Injector Replacement

Special Tools

    • EN-34730-91 Fuel Pressure Gauge
    • CH-807 Closure Plugs

For equivalent regional tools, refer to Special Tools .

Removal Procedure

  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:
  5. 4.1. Evaporative emission purge valve
    4.2. Fuel injectors
  6. Place a collecting basin underneath.
  7. 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.

  8. Release the fuel pressure using the test connection with EN-34730-91 gauge .

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

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  13. Remove the 2 evaporative emission canister purge solenoid valve bracket bolts (2).
  14. Remove the evaporative emission canister purge solenoid valve bracket (1) from the intake manifold (7).
  15. Remove the 2 multiport fuel injection fuel rail bolts (3).
  16. Remove the multiport fuel injection fuel rail (4) with the fuel injectors (5) from the intake manifold (7).
  17. Remove the 4 fuel injector seals (6).

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  19. Remove the fuel injector retainer (1).
  20. Remove the fuel injectors.

Installation Procedure


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  1. Install the fuel injectors.
  2. Note: Install NEW fuel injector seals, coat the multiport fuel injector seals with silicone grease.

  3. Install the fuel injector retainer (1).

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    Note: Coat the fuel injector seals with silicone grease.

  5. Install the 4 NEW fuel injector seals (6).
  6. Install the multiport fuel injection fuel rail (4) and the fuel injectors (5) to the intake manifold (7).
  7. Caution: Refer to Fastener Caution in the Preface section.

  8. Install the 2 multiport fuel injection fuel rail bolts (3) and tighten to 8 N·m (71 lb in).
  9. Install the evaporative emission canister purge solenoid valve bracket (1) to the intake manifold (7).
  10. Install the 2 evaporative emission canister purge solenoid valve bracket bolts (2) and tighten to 8 N·m (71 lb in).

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  12. Remove the CH-807 plug .
  13. Connect the quick-release fitting of the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the wiring harness to the:
  15. 10.1. Evaporative emission purge valve
    10.2. Fuel injectors
  16. 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 .
  17. Connect the negative cable to the battery. Refer to  Battery Negative Cable Disconnection and Connection : without Start/Stop System .
  18. Close the bonnet.
   


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