Injector and fuel rail installation components
1 - Sealing ring (brown); 2 - Injector lock; 3 - Sealing ring (black); 4 - Fuel distribution line; 5 - Fuel supply pipe; 6 - Injector
1. Release the pressure in the fuel system (see section Relieving pressure in the fuel system).
2. Remove the air intake sleeve and air cleaner cover assembly (see section Removal and installation air intake tract components).
3. Remove the intake manifold support bracket (see section Removal and installation the intake manifold).
4. Disconnect the fuel hose from the fuel rail and plug it to prevent fuel leaks.
5. Disconnect the injector wiring and move it to the side. If disconnecting the connectors is difficult, this can be done after removing the fuel rail and injector assembly from the cylinder head.
6. Remove the fuel rail mounting bolts (first the bolt closest to the rear of the engine) and remove the fuel rail and injector assembly from the cylinder head.
Note: Do not allow the injector nozzles to touch other parts.
7. Remove the injectors from the distribution line, having first pulled out the injector retainer.
Note: Remove the injectors without tilting, do not damage the sprayers. Do not drop the injectors, do not disassemble or adjust.
8. When installing the injector sealing rings, remember the following things:
- The upper and lower sealing rings are different from each other, install them according to the color marking: brown - on the distribution side, and black - on the cylinder side;
- Install the O-rings with bare hands, do not wear gloves;
- Before installation, lubricate the O-rings with engine oil;
- Do not clean O-rings with solvents;
- Sealing rings and mating surfaces must be free of foreign materials;
- Do not scratch the O-rings with tools or fingernails, or twist or stretch the rings.
9. Install new retainer (3) into the corresponding groove (2) on the injector (1). The bracket (5) of the retainer must go onto the protrusion (4) on the injector. Make sure that the retainer does not touch the sealing ring. Otherwise, replace the sealing ring.
10. Install the injector (1) evenly into the distribution line (6). The notch (8) on the retainer must fit into the protrusion (7) on the distribution line, and the flange (10) must sit securely in the groove (9) of the retainer.
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11. Make sure that the injector does not rotate or come out of the distribution line. Repeat the procedure from step 9 for the remaining injectors.
12. Install the injector and fuel rail assembly onto the cylinder head, preventing the nozzles from touching other parts, and tighten the assembly mounting bolts first with force 11.8÷13.8 Nm, and then with effort 20.8÷28.2 Nm.
Note: Tighten the bolt closest to the front of the engine first.
13. Connect the fuel hose to the fuel line and tighten its clamp securely.
14. Install the intake manifold support bracket and tighten its mounting bolts in the sequence shown in the illustration, first by hand and then with force 6.9÷9.5 Nm (bolt no. 1) or 8.4÷10.8 Nm (bolts #2 and #3).
15. Further installation is carried out in the reverse order of dismantling the components.
16. After installation, turn on the ignition (without starting the engine) after pressurizing the fuel system, check for fuel leaks. Then start the engine and check the fuel lines again for leaks.