Be especially careful! Do not place your hands or other body parts under the injector nozzles!
Do not allow dirt to enter the fuel system tract!
Remember that injectors are precision equipment and should be handled with extreme care!
1.7L SOHC Models
1. Disconnect the fuel return lines from the injectors.
2. Thoroughly wipe the union connectors connecting the fuel lines to the injectors, then loosen the union nuts. When disconnecting the tubes from the pump, hold the mating part of the 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 injector body, but also its base, since otherwise there is a high risk of internal components falling out, and assembly will require a number of adjustments, which can only be performed in a car service workshop.
4. Remove the seals from the injector seating holes (flame retardant) 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 injector condition requires the use of special equipment and should be entrusted to car service specialists.
6. Begin installation by placing the seals in the cylinder head (flame retardant) washers.
7. Carefully screw in the injectors and tighten them to the required torque.
8. Finally, install the fuel lines and ensure that the union nuts are tightened to the required torque.
Models 1.7L DOHC
1. Remove the timing cover (see Chapter Engine).
2. Remove the five mounting bolts and the inner fuel return line. Remove the copper sealing washers. New copper sealing washers are installed on both sides of the fuel return line nipple connectors to the injectors.
The washers of the connectors connecting the tubes to the timing case are also subject to replacement.
3. Loosen the mounting nuts and remove the injector mounting clamps.
4. Remove the injectors from the cylinder head, the copper sealing washers must be replaced. Discard the rubber seals and copper washers. Try not to attempt to disassemble the injectors yourself.
5. Diagnostics of the injector condition requires the use of special equipment and should be entrusted to car service specialists.
6. Begin assembly by cleaning the mating surfaces of the injectors and the cylinder head. Install new rubber and copper seals on each injector - make sure the copper washers are positioned correctly.
7. Install the injectors into the cylinder head and secure them with mounting clamps. Tighten the clamp mounting nuts to the required torque.
8. Connect the fuel return line to the timing case and injectors. The tube is secured to the timing case using a larger diameter bolt (don't forget to replace the copper sealing washer), new copper sealing washers should be installed on the top of the injector and under each bolt. Tighten the bolts to the specified torque.
9. Install the timing case cover (see Chapter Engine).
10. Start the engine and check for signs of developing leaks.
2.0L models
To remove the injector nozzle from the cylinder head, you will need the KM-928-B puller with the KM-931 adapter mandrel. New adapter tube bolts will be required for installation.
1. Remove the upper section of the intake manifold (see above Models 1.7L DOHC, p.7).
2. Remove the camshaft and valve drive levers (see Chapter Engine).
3. Disconnect the return pipe from the injector adapter pipe.
4. Loosen the mounting bolt, carefully separate the adapter tube from the top of the injector nozzle and remove it from the cylinder head.
5. Remove the sealing rings from the adapter tube and the upper part of the injector nozzle - the rings must be replaced without fail.
6. Install the 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 sealing rings installed in the base of the nozzle - the rings must be replaced during assembly.
7. Place new sealing rings on the nozzle bases, then carefully insert the nozzles into the top of the cylinder head, ensuring that their guide pins are correctly aligned with the recesses in the head.
8. Make sure that the injector nozzle fits tightly in the cylinder head, place a new sealing ring on its upper part.
9. Place new sealing rings into the lugs on the adapter tubes. Install the adapter tubes in their proper places in the cylinder head, making sure they are positioned correctly on the top of the injector nozzles. Screw in new mounting bolts, tighten them until they stop by hand.
10. Then tighten the key another full turn (360°).
11. Connect the return line to the adapter tubes and install the upper part of the inlet pipe (see Removal and installation the intake manifold).
12. Install the camshaft and valve drive levers in place (see Chapter Engine).
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