Take special care! Do not place your hands or other parts of your body under the nozzles!
Do not allow dirt to enter the path of the power system!
Remember that nozzles are precision equipment and should be handled with extreme care!
Models 1.7L SOHC
1. Disconnect the fuel return lines from the injectors.
2. Thoroughly wipe the nipple connectors for connecting to the injectors of the fuel lines, then loosen the union nuts. When disconnecting the tubing from the pump, hold the mating connector with a second open end wrench. After disconnecting the connectors, remove the fuel lines from the engine, immediately collect spilled fuel with a clean rag.
3. Wipe the surfaces around the injectors and remove the latter from the cylinder head.
Unscrew not only the nozzle body, but also its base, otherwise there is a high risk of internal components falling out, and assembly will require a number of adjustments, which are only possible in a car service workshop.
4. Remove the sealing (flameproof) washers, when assembling the washers must be replaced without fail. Try not to attempt to disassemble the injectors on your own.
5. Diagnostics of the state of the injectors requires the use of special equipment and should be entrusted to car service specialists.
6. Start the installation by placing the seals in the cylinder head (flameproof) washers.
7. Carefully screw in the nozzles and tighten them to the required torque.
8. Finally, install the fuel lines and make sure the union nuts are tightened to the correct torque.
Models 1.7L DOHC
1. Remove the timing cover (see chapter Engine).
2. Turn out five fixing bolts and remove an internal line of return of fuel. Remove copper sealing washers. New copper sealing washers are installed on both sides of the nipple connectors for connecting the fuel return line to the injectors.
The washers of the connectors for connecting the tubes to the timing case must also be replaced.
3. Give fixing nuts and remove mounting collars of atomizers.
4. Remove the nozzles from the cylinder head, copper sealing washers must be replaced without fail. Discard rubber seals and copper washers. Try not to attempt to disassemble the injectors on your own.
5. Diagnostics of the state of the injectors requires the use of special equipment and should be entrusted to car service specialists.
6. Start assembly by cleaning the mating surfaces of the injectors and cylinder head. Install new rubber and copper sealing elements on each nozzle - follow the correct placement of the copper washers.
7. Establish nozzles in a head of cylinders and fix them with assembly collars. Tighten the clamp nuts to the required torque.
8. Connect the fuel return line to the timing case and injectors. The tube is attached to the timing case by means of a larger diameter bolt (don't forget to replace the copper sealing washer), new copper sealing washers must be installed on the top of the nozzle and under each bolt. Tighten the bolts to the prescribed torques.
9. Install the timing case cover (see chapter Engine).
10. Start the engine and check for signs of leaks.
Models 2.0 l
To remove the nozzle sprayer from the cylinder head, a KM-928-B puller with a KM-931 adapter is required. New adapter tube bolts will be required during installation.
1. Remove the top section of the intake manifold (see above Models 1.7L DOHC, item 7).
2. Remove the camshaft and valve levers (see chapter Engine).
3. Disconnect the return tube from the nozzle adapter tube.
4. Turn out a fixing bolt, accurately separate an adapter tube from the top part of atomizer of atomizer and take its cylinder heads.
5. Remove the sealing rings from the adapter tube and the upper part of the nozzle sprayer - the rings must be replaced without fail.
6. Place a mandrel and puller on the top of the injector nozzle and evenly and carefully remove the nozzle from the top of the cylinder head. Remove and discard the o-rings installed in the base of the atomizer - the rings must be replaced without fail during assembly.
7. Place new o-rings on the nozzle bases, then carefully place the nozzles on top of the cylinder head, making sure their guide pins line up with the notches on the head.
8. Make sure that the injector nozzle is firmly seated in the cylinder head, place a new sealing ring on its upper part.
9. Fit new o-rings into the lugs on the adapter tubes. Install the adapter tubes in their regular places in the cylinder head - make sure that they are correctly placed on the top of the injector nozzles. Screw in new mounting bolts, tighten them until they stop by hand.
10. Then tighten the wrench one more full turn (360°).
11. Connect the return line to the adapter pipes and install the upper part of the inlet pipeline (see Removal and installation of the inlet pipeline).
12. Reinstall the camshaft and valve levers (see chapter Engine).
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