Note: Before you begin, please read the warning provided in paragraph 1.
Note: If you suspect a faulty injector, try using one of the commercially available injector cleaners before removing the injectors.
Models with 1.4L engine
1. Disconnect the ground cable from the battery (see "Disconnecting the battery").
2. Remove the air cleaner assembly as described in paragraph 2.
3. On later models with the ignition coil pack mounted above the fuel rail, remove the coil pack as described in chapter 5B.
4. Disconnect the accelerator cable (if applicable) from the cam on the throttle body, then pull the cable housing along with the corresponding spring clip out of the rubber grommet in the support bracket.
5. Remove the screws and the accelerator cable bracket from the manifold/cylinder head (figure 13.5).
Figure 13.5. Remove the screws (marked with arrows) and remove the accelerator cable bracket (models with a 1.4 L engine)
6. On early models, disconnect the vacuum line from the fuel pressure regulator.
7. Taking into account the information given in paragraph 7, disconnect the fuel supply hose, and on earlier models, the return hose. To do this, you should release the clamps or disconnect the quick-release couplings (figure 13.7).
Figure 13.7. Press the clamp (marked with an arrow) and disconnect the fuel hose from the fuel rail (models with a 1.4 L engine)
8. Unscrew the two bolts securing the fuel rail to the cylinder head and unscrew the nut securing the fuel rail to the manifold. Loosen the bolt securing the fuel rail center bracket to the intake manifold, then remove the bracket (the bracket has a groove for easy removal) (figure 13.8, a, b).
Figure 13.8, a. Loosen the bolts (1) and unscrew the nut (2) securing the fuel rail...
Figure 13.8, b....then release the bolt (marked with an arrow) and remove the central bracket
9. Disconnect the injector wiring harness electrical connector, and then release the electrical connector from the clamp on the rear of the intake manifold. Also disconnect the electrical connectors at the throttle body and move the wiring harness away from the manifold so that it does not interfere with removal of the fuel rail.
10. Carefully remove the fuel rail assembly with injectors from the cylinder head and remove the unit from the engine compartment. Remove the seals from the end of each injector and discard them; they should be replaced each time they are removed (figure 13.10).
Figure 13.10. Remove the seal from the end of each injector (models with a 1.4 L engine)
11. Disconnect the electrical connector, then remove the clamp and remove the corresponding injector from the fuel rail. Remove the top seal from the injector(s) and discard; after removal, seals must be replaced (figure 13.11, a, b).
Figure 13.11, a. Disconnect the electrical connector...
Figure 13.11, b....then remove the clamp and remove the injector from the fuel rail (models with a 1.4 L engine)
12. Installation is carried out in the reverse order of removal, taking into account the following points:
- a) Install new seals on all removed injectors (figure 13.12).
Figure 13.12. Replace all seals on the removed injector (models with a 1.4 L engine)
- b) To facilitate installation, apply a small amount of engine oil to the seals, then install the injectors and fuel rail into place, ensuring that none of the seals are displaced.
- c) Finally, connect the battery and increase the pressure in the fuel system as described in paragraph 7. Start the engine and check for fuel leaks.
Models with 1.6L engine
13. Remove the intake manifold as described in paragraph 14.
14. Unscrew the two bolts and remove the fuel rail together with the injectors from the manifold (figure 13.14).
Figure 13.14. Remove two bolts (marked with arrows) and remove the fuel rail from the manifold (models with a 1.6 L engine)
15. Disconnect the electrical connector, then remove the clamp and remove the corresponding injector from the fuel rail (figure 13.15). Remove the seals from each removed injector and discard them; all damaged seals should be replaced.
Figure 13.15. Remove the clamp and remove the corresponding injector from the fuel rail (models with a 1.6 L engine)
16. Installation is carried out in the reverse order of removal, taking into account the following points:
- a) Install new seals on all removed injectors (figure 13.16).
Figure 13.16. Replace all seals on the removed injector (marked with arrows) (models with a 1.6 L engine)
- b) To facilitate installation, apply a small amount of engine oil to the seals, then install the injectors and fuel rail into place, ensuring that none of the seals are displaced.
- c) Finally, connect the battery and pressurize the fuel system as described in paragraph 7. Start the engine and check for fuel leaks.