Note: Observe the precautions given in Chapter 1.
Warning: Handle fuel injectors with extreme care. Never put your hands or any part of your body under the nozzle jet. It is strongly recommended that any work that involves checking the operation of the pressure injectors be performed by a fuel injection specialist or dealer. Before starting work, see the precautions given in Chapter 1 from this section.
General description
1. Injectors wear out over time and it is reasonable to expect they will need to be repaired or replaced after 100,000 km. An accurate check of serviceability, overhaul and calibration of injectors must be entrusted to a specialist. A defective injector that may be causing detonation or smoke can be identified without disassembly as follows.
2. Start the engine, set the fast idle mode. Slowly loosen the coupler on each nozzle one at a time. When the coupling on the defective injector is loosened, knocking or smoking should stop.
Withdrawal
Note: Be very careful not to let dirt get into the injectors or fuel lines. Don't drop the injectors!
3. Disconnect the negative cable from the battery.
4. Where applicable, remove the top cover from the engine.
5. Carefully clean the area around the injectors and fuel line coupling nuts and disconnect the outlet hoses from the injectors (see illustration).
6. Wipe the fuel line couplings, then loosen the union nuts securing the tubes to each injector and the union nuts securing the tubes to the back of the fuel pump (tubes are removed as one assembly). Remove the injector tubes from the engine. Close the nozzle and fuel line couplings to prevent dirt from entering the system (see illustrations).
7. Injectors 4 and 5 can be accessed by removing the extension element bracket and idle control bracket.
8. Clean the area around the base of the injectors, then unscrew and remove them from the cylinder head.
Warning: Be sure to unscrew the injector holder from the cylinder head and remove the complete assembly, not the injector body from the holder. If the body is unscrewed from the holder, the small internal components of the nozzle will be disturbed, and it will be necessary to contact a specialist to assemble and check the nozzles.
9. Remove the fireproof washers from the injector sockets in the cylinder head.
Installation
10. Clean the nozzle seats and the threads in the cylinder head.
11. Install new fire-resistant washers in the cylinder head, making sure they are correctly oriented. The outer rim of the washers should be facing up.
12. Apply a small amount of anti-jamming compound to the threads of the injectors, then screw them into the cylinder head and tighten to the specified torque.
13. Install the idle speed control and extension element brackets and tighten the bolts.
14. Connect the tubes to the injectors and the fuel pump, and tighten the nuts.
15. Connect the outlet hoses, and tighten the clamps where necessary (see illustration).
16. Where applicable, install the top cover on the engine.
17. Connect the wiring to the battery.
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