Fuel Injector: Service and Repair

Removing And Installing Injection Valve

No. 1 - 9:

Removing injection valve
- Ignition off, ignition key removed.
- No sources of ignition in the vicinity
- Ensure that there is adequate ventilation.

CAUTION:
- Danger of fire.
- Danger of poisoning.
- No open fire or sources of ignition in the vicinity of the fuel system.
- Fuel is poisonous. Avoid contact with skin and eyes. Do not inhale fumes.
- Use appropriate protective equipment (goggles, gloves).

1. Remove engine compartment cover on the right side. To do this unscrew the 4 bayonet screws and the fastening screw on the windshield washer reservoir.
2. Unscrew the torque support. To do this unscrew the fastening screw on the torque support bracket and pull it out.







3. Unscrew the torque support on the body and swivel upwards.







4. Release the secondary air pump from the cylinder bank 1 - 4. To do this unscrew the 3 fastening screws, remove the pump from the holder and place it on one side.







5. Unscrew the 4 fastening screws on the design cover.







6. Remove design cover from the cylinder bank 1 - 4. Lift the cover slightly with both hands on the side pointing towards the intake system until it snaps out of the mounting bosses.







7. Lift the cover on the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Then pull off the cover to the front.







8. Unscrew the 4 fastening screws on the design cover.







9. Remove design cover from the cylinder bank 5 - 8. To do this lift the cover slightly with both hands on the side pointing towards the intake system until it is released from its retainer.







10. Lift the front of the design cover and remove it.







11. Pull the throttle body cover vertically upwards.







12. Disconnect the fuel line. To do this separate the connector on the water chamber splash board. Collect emerging fuel.







13. Separate all 8 connectors on the injection valves. To do this, press the metal clip and pull off the connector.







14. Unscrew the 4 fastening screws with a Torx key 30 on the fuel distribution pipe.







15. Remove fuel distribution pipe with the injection valves.
16. Remove the mounting element from the injection valve -A- and pull the injection valve out of the fuel collection pipe -B-.







Installing injection valve

NOTE: If the injection valves are to be reused, the sealing rings should be replaced.

1. Replace sealing rings on the injection valves. Take care not to damage the injection valve when removing the sealing rings.
2. Insert injection valve in the fuel distribution pipe -A- and align. The electric connector must be positioned against the lug on the distributor. Then install a new sheet metal clip.

Valve alignment







View shows fitting







3. Check that the sheet metal clamp is correctly fitted. The sheet metal clip must engage in the bordering edge on the fuel collection pipe.







4. Insert injection valves into the openings in the intake module and press the fuel gallery down.
5. Tighten the 4 fastening screws to 8 Nm (6.0 ftlb.).







6. Slide on all 8 electric connectors on the injection valves. The connectors must engage audibly.







7. Connect fuel line at the connection point on the plenum panel. The connector must engage audibly.







8. Switch on ignition and check the system for leaks.
9. Press the 4 rubber elements in the cover onto the 4 ball socket holders. The fastening elements must lock in firmly.







10. Slide the design cover of the cylinder bank 1 - 4 under the secondary air pump as shown in the picture and then slide the cover of the second ignition coil through underneath the torque support bracket.







11. Press down the 2 rubber mounts on the support. The rubber mounts must engage firmly.







12. Tighten the 4 fastening screws on the ignition coil to 4 - 5 Nm (3.0 - 3.5 ftlb.).







13. Reinstall secondary air pump. Tighten the 3 fastening screws to 10 Nm (7.5 ftlb.).







14. Reinstall torque support. Install the fastening screw (M10 x 70) with a new fastening nut on the bracket. Tightening torque 60 Nm (44 ftlb.).







15. Tighten torque support fastening screw on the body (M10 x 20) to 60 Nm (44 ftlb.).
16. Install engine compartment cover on the right side. To do this tighten the 4 bayonet screws and the sheet metal screw on the windshield washer reservoir.
17. Slide design cover under the secondary air pump as shown in the picture.







18. Then press down the 2 rubber mounts on the support. The rubber mounts must engage firmly.







19. Tighten the 4 fastening screws on the ignition coil to 5 Nm (3.5 ftlb.).







Tightening torques