Fuel Injector: Service and Repair

Fig. 1:

Fig. 2:

Remove
- Reposition top edge of trunk front liner.
- Disconnect multi-plug from evaporative loss flange inset.
- Switch ignition on. Crank engine to depressurize fuel system.
- Switch ignition off. Disconnect battery see Section 15.
- Remove engine cover, See section 3.2.
- Remove engine cover 1/4 turn fastener receptacles (1 Fig.1)from fuel rail (2 Fig.1).
- Undo fuel feed hose to fuel rail union nut (3 Fig. 1).
- Reposition fuel feed hose (4 Fig. 1) from fuel rail and discard green seal.
- Undo fuel return hose to fuel pressure regulator union nut (5 Fig. 1).
- Reposition fuel return hose (6 Fig. 1) from fuel pressure regulator and discard green seal (7 Fig. 1).
- Disconnect vacuum hose (1 Fig.2) from cruise control actuator (2 Fig.2).
- Disconnect vacuum hose (3 Fig.3) from fuel pressure regulator.
- Disconnect throttle control rods from throttle pulley assembly ball pins (4 Fig.2).
- Reposition throttle control rods to inner wings.
- Disconnect cruise control rod from throttle pulley assembly ball pin (5 Fig.2).
- Undo and remove bolts securing fuel rail.
- Reposition cruise control rod below throttle pulley assembly.
- Remove cruise control actuator/bracket assembly and fixings (6 Fig.2).
- Disconnect injector harness plugs (7 Fig.2).
- Disconnect throttle potentiometer multi-plug (8 Fig.2)
- Remove throttle pulley bracket assembly and fixings (9 Fig.2)
- Remove injector harness plastic clips (10 Fig.2) from fuel rail.
- Remove fuel rail / injector assembly (11 Fig.2).

Fig. 3:

- Remove injector to fuel rail retaining clips (1 Fig.1).
- Remove injector (2 Fig.1).
- Remove fuel regulator retaining plate and fixings (3 Fig.1).
- Remove fuel regulator (4 Fig.1).
- Remove and discard O-ring seals from regulator and injectors.

Refit
- Fitting new components is the reverse of the removal procedure.
- Ensure new green seals are fitted to fuel feed and return pipes.
- Fit new O-ring seals to regulator and injectors.