For 1990-2009 cars

#### Special Tools

1. EN-46786 Injector removal tool
2. DT-49407 Sliding hammer
3. EN-32025012 Sliding hammer adapter
4. EN-47632 Cleaning tool

### Removal Procedure

Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

Warning: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:

• | Use forced air ventilation such as a fan set outside of the trunk.

• | Plug or cap any fuel system openings in order to reduce fuel vapor formation.

• | Clean up any spilled fuel immediately.

• | Avoid sparks and any source of ignition.

• | Use signs to alert others in the work area that fuel system work is in process.

Warning: Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.

Warning: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Note: Be very thorough in terms of cleanliness when working in the fuel system. Malfunctions can also occur due to very small dirt particles. Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal. Store the components so that contaminants cannot enter.

Warning: Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.

Note: If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.

1. Open the bonnet.
2. Remove the upper engine cover and insulation.
3. Remove the connectors (3) from the injectors.
4. Remove the fuel return hoses (4).
5. Remove the fuel pipes from the injectors and fuel rail (5). Hold the injector with a spanner when detaching the pipe.
6. Remove the cables from the crankcase ventilation pipe (6).
7. Remove the crankcase ventilation pipe (7).
8. Remove the injector with holder (8). If the nozzles cannot be lifted by hand, use EN-46786 removal tool , DT-49407 sliding hammer and EN-32025012 adapter .
9. Remove the injectors in the following order: 1-2-3-4

Note: If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.

10. Clean the injector sealing surfaces in the cylinder head using EN-47632 cleaning tool (10).

### Installation Procedure

Note: If new injectors are to be fitted, read and make a note of its classification code. The code is to be used when programming using the diagnostic tool.

1. Install the injectors with NEW seals in the following order: 4-3-2-1. Tighten: 25 N·m (18 lb ft).
2. Install the crankcase ventilation pipe (2).
3. Install the cables to the crankcase ventilation pipe (3).
4. Check that the fuel pipe sealing surfaces are not damaged and are clean. Install the pipes (4) without force and start the nuts by hand. Tighten to injectors: 19 N·m (14 lb ft). Tighten to pump: 25 N·m (18 lb ft).
5. Install the fuel return hoses.
6. Install the connectors.
7. If new injectors are installed, connect the diagnostic tool for programming.
8. Start the engine and check that the fuel system is not leaking. Connect the diagnostic tool and erase any diagnostic trouble codes.
9. Install the upper engine cover.