Warning! When checking the operation of the fuel injectors, never place your hands or any part of your body under the jet of fuel coming out of the injector. The fuel exits the nozzle at high pressure and can enter the body through the skin.
1.7L engines
Location of fuel injector parts
A - high temperature bushing
B - heat-insulating washer
C - sealing ring
1. Remove the intake manifold to access the fuel injectors.
2. Remove the fuel lines from the fuel pump to the fuel injectors.
3. Remove the nuts from the top of the fuel injectors and remove the fuel return pipe.
4. Unscrew the fuel injectors and remove them from the cylinder head.
5. Remove the O-ring, heat insulating washer and high temperature bushing from the fuel injector seat.
6. Fuel injectors must be checked at a service station using special equipment.
7. Install a new high temperature bushing into the fuel injector seat.
8. Install a new heat insulating washer in the fuel injector seat.
9. Install the O-ring into the fuel injector seat.
10. Install the fuel injectors into the cylinder head and tighten them to the required torque. If the fuel injector is properly secured, the mark on the injector body (bottom arrow) must align with the lug on the cylinder head (top arrow).
11. Install the fuel return pipe with new washers on the fuel injectors and secure with nuts, tightening them to the required torque.
12. Install the fuel supply pipes from the fuel pump to the fuel injectors.
13. Install the intake manifold.
14. Start the engine and check the fuel system for leaks.
2.0L engines
1. Remove the upper section of the exhaust manifold.
2. Remove the camshaft and levers.
3. Disconnect the fuel return pipe from the bypass pipe.
4. unscrew the bolt (indicated by an arrow), release the bypass pipe from the top of the fuel injector and remove it from the cylinder head.
5. Remove the o-rings from the bypass pipe and top of the fuel injector.
6. Using an adapter and puller, remove the fuel injector from the top of the cylinder head and remove the O-ring.
7. Install a new O-ring on the bottom of the fuel injector.
8. Install the fuel injector into the cylinder head, aligning the dowel pin (top arrow) with cylinder head groove (bottom arrow).
9. Install a new O-ring to the top of the fuel injector.
10. Install a new O-ring into the groove of the cross tube. Install the cross bypass pipe into the cylinder head and secure it with a new bolt.
11. Tighten the bolt by hand first.
12. Then, using a wrench, tighten the bolt 360°.
13. Connect the return pipe to the bypass pipe and install the top section of the manifold.
14. Install the camshaft and levers.
15. Start the engine and check the fuel system for leaks.
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