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Injectors

Injectors


To remove

Important

Scrupulous cleanliness must be observed when carrying out any work on the fuel rail and injectors. Thoroughly wash the area round the injectors, fuel rail and intake manifold and blow dry with compressed air.



1. Remove the engine covers.

Warning

Since replacement of the injectors entails working on the car's fuel system, the following points should be observed in connection with installation:

Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapour is available, be sure to use it.

Wear suitable gloves. Prolonged contact with fuel may give rise to skin irritation or dermatitis.

Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short-circuits and when connecting and disconnecting leads, etc. in electrical circuits.

No smoking anywhere in the vicinity.


2. Undo the hose clips on the rubber duct. Disconnect the IAC valve's hose and unplug the rear knock sensor's connector from the duct. Remove the rubber duct. Undo the intake manifold's retaining stay and cable conduits.


3. Disconnect the throttle and Cruise Control cables from the throttle lever and bracket. Also disconnect the crankcase ventilation and brake servo vacuum hoses.

4. Remove the seven nuts securing the upper half of the intake manifold.

5. Raise the upper half of the intake manifold and support it by means of a rubber mallet or the like. Plug the intake manifolds with paper or rags to prevent screws and the like from falling down into the cylinders.

6. Unplug the connectors from all injectors.


7. Undo the fuel rail's seven retaining bolts.

Using a screwdriver, ease the fuel rail loose.

8. Remove the retaining clip from the injector or injectors that are to be inspected or replaced.

Wrap the injector in a cloth to catch any dripping fuel and then withdraw the injector from the fuel rail.

Note

For replacement of the fuel rail or fuel pressure regulator, see Service Manual 2:3 .



To fit


1. Inspect the O-rings at both ends of the injector. Smear them with a little petroleum jelly (Vaseline) to facilitate fitting.


2. Fit the injector or injectors in the fuel rail and refit the retaining clip.

3. Fit the fuel rail in place and tighten it.

4. Plug in the injector connectors.

5. If necessary, clean the mating surface of the intake manifold. Remove the paper or rags from the intake manifold and fit a new gasket.

Position the upper half of the intake manifold correctly.

6. Tighten all the nuts securing the upper half of the intake manifold. Start with the nuts in the middle and continue alternately towards the outer ends of the manifold.


Tightening torque: 20 Nm (15 lbf ft)

7. Tighten the retaining stay at the rear of the intake manifold. Refit the cable conduits.


Tightening torque: 20 Nm (15 lbf ft)

8. Make sure that the pressure regulator's vacuum hose is connected to the front nipple on the throttle body (in front of the butterfly).

9. Reconnect the vacuum hoses for the brake servo and crankcase ventilation. Refit the throttle and Cruise Control cables to the throttle lever and mounting bracket.

10. Fit the rubber duct and tighten the hose clip. Connect the IAC hose and plug the rear knock sensor's connector into the duct.

11. Fit the engine covers back in place.