Procedures

244020 Removing And Installing Fuel Injector

Preliminary work for removing fuel injector
1. Place protective covers on the vehicle to avoid damaging the body.
2. Disconnect battery ground lead.
3. Remove engine compartment lid.
4. If a fuel injector from cylinder 1 to 3 is removed, the air-cleaner element must be removed.

Removing fuel injector

DANGER: Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.
- The following work procedure is shown on the fuel gallery of cylinders 1 - 3 as an example.

1. Release and pull off cable plug -1-).
2. Unscrew two Torx screws (M6 x 10) -2- on the fuel gallery.

Left Fuel Gallery:

3. Pull fuel injectors with fuel gallery out of the bores in the intake-air distributor or intake pipe support.
4. Lever off safety clips -arrow-.

Fuel Injector Clips:

5. Pull fuel injector out of the fuel gallery.

Installing Fuel Injector

1. Replace O-rings -arrows-. Lightly grease new O-rings with Optimal MP3.

Fuel Injector:

2. Press fuel injector into the fuel gallery.
3. Fit safety clips.
4. Press fuel injectors with fuel gallery into the bores in the intake-air distributor or intake pipe support.
5. Secure fuel gallery with two Torx screws (M6 x 12) -2-.
Tightening torque 7.5 ftlb.
6. Connect fuel injector cable plug -1-. The plug must engage audibly.

Left Fuel Gallery:

Subsequent work for installing fuel injector
1. If a fuel injector from cylinder 1 to 3 was removed, the air-cleaner element must be installed.
2. Connect battery ground lead.
3. Carry out an engine test run. Make sure the fuel injectors are fully sealed.
4. Install engine compartment lid.
5. Read out fault memory and correct any faults that are present. Erase fault memory.