Attention! See precautions in subsection 6.3.2 before starting work.
Attention! If you think an injector has failed, try cleaning it with an appropriate injector cleaner such as Holts Redex Injector Treatment.
Fuel Supply Hose and Fuel Rail Return Hose - 1.6L Engine Models
The fuel supply hose and fuel manifold return hose are indicated by arrows.
Removing
1. Disconnect the negative battery cable. To improve access to the fuel rail, remove the air cleaner cover following the instructions in subsection 6.3.2.2.
2. Disconnect the vacuum tube from the fuel pressure regulator.
3. Release pressure from the fuel system following the instructions in subsection 6.3.2.6. Then, release the fastening clips and disconnect the fuel supply hose and the return pipe hose from the left side of the fuel manifold (see fig. Fuel Supply Hose and Fuel Rail Return Hose - 1.6L Engine Models). Mark the hoses, if necessary, to avoid confusion during installation.
4. Squeeze the tabs and disconnect the connection connectors from the four injectors.
5. Loosen and remove the fuel manifold mounting bolts, then carefully remove the fuel manifold and injectors from the intake manifold and remove it from the engine compartment. Remove the gaskets installed between the fuel manifold and the intake manifold and remove the injector seals from the intake manifold.
6. Unscrew the two mounting bolts and remove the mounting plate from the corresponding injector. Squeeze out the injector and remove the sealing rings. Remove the rest of the injectors in the same way.
7. Discard seals and o-rings; when installing, you must use new ones.
Installation
1. Installation is carried out in the reverse order of removal. Install new O-rings on the injectors that were removed, and install new injector seals on the intake manifold.
2. Lubricate the o-rings with engine oil to facilitate installation, then install the injectors on the fuel rail;
3. Install a new seal on each of the injectors and install the fuel manifold onto the intake manifold.
4. Install the gaskets between the fuel rail and the intake manifold, then, diagonally from the middle, tighten the mounting bolts to the correct stage 1 torque (see subsection 6.3.2.1). Then, again, in the same order, tighten the bolts to the required stage 2 torque.
5. After installation is complete, start the engine and check for fuel leaks.