Removal And Installation

NOTE:

The "GSE INJECTOR ADAPTATION" scan tool procedure should always be run after a PCM, fuel injector, fuel rail, high pressure pump or fuel pressure sensor is replaced. The procedures should be in the "Miscellaneous Functions" tab in the PCM. Failure to run the procedures may cause DTCs to set in the PCM.

REMOVAL

Perform the fuel pressure release procedure. Refer to FUEL DELIVERY, STANDARD PROCEDURE .
Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .

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Thoroughly clean the area around the fuel line nuts to prevent contaminants from entering the fuel system.
Loosen the fuel line nuts (1, 2a) and remove the high pressure fuel line (2b).
NOTE:
The high pressure fuel line can be reused if the injection pump and fuel rail are being reused, otherwise the high pressure fuel line must be discarded and replaced.

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Unlock and disconnect the fuel pressure sensor wire harness connector (1).

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Disconnect the oil temperature sensor wire harness connector (1).

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Disconnect the oil vapor line (1) from cam cover and position aside.

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Remove the fuel rail bolts (1a) from the fuel rail (1b). Loosen the outer two bolts before the inner two bolts. DISCARD the fuel rail bolts, they can not be reused.

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Unlock and disconnect the fuel injector wire harness connectors (1).
Remove the fuel rail complete with fuel injectors and fuel pressure sensor.

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NOTE:
The fuel injectors are not fastened to the fuel rail.
If one or more injectors should remain in the cylinder head, remove them using the (special tool #2066100140, Remover, Fuel Injector), as shown in the illustration.
NOTE:
Thoroughly clean the tool prior to use to prevent contaminants from entering the fuel system.

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For difficult to remove injectors, install the (special tool #2066100140, Remover, Fuel Injector) (1) in the fuel rail bolt hole and lever the injector remover with a screwdriver as shown in illustration.

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Remove the fuel injectors (1b) from the fuel rail complete with back-up rings and O-rings (1c).
If required, remove the fuel rail pressure sensor (1a).

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The O-rings (1c), back-up rings (1b) and injector seals (1a) must be replaced once they have been removed. The O-rings, back-up rings and injector seals should never be reused. Remove and install the rings and seals one injector at a time, using the (special tool #2072700140, Kit, Fuel Injector 1.3L) as described below.

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With the (special tool #2025505140, Pliers, Injector Seal Removal) (1a) partially remove the injector seal (1b).
NOTE:
Use care during this step to not damage the injector body. Select the 7.8 mm jaw size (larger hole) to score the injector seal.

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Finish removing the injector seal using the (special tool #2025504140, Pick, Injector Seal 90 Degree) (1a) and the (special tool #2025506140, Pliers, Injector Seal Side Cutter) (1b).

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Remove the retaining clip (1).

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Position the Clip, Fuel Injector 2072701140 (1) from the kit on the injector.
Remove the O-ring (2).

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Using a suitable tool, remove the back-up ring (1a), being careful not to damage the fuel injector sealing surface (1b).

INSTALLATION

Thoroughly clean the fuel injector tip with a soft cloth and solvent.
Install the NEW O-rings, back-up rings and injector seals on each injector, using the (special tool #2072700140, Kit, Fuel Injector 1.3L) as described below.

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Insert the NEW back-up ring (1a) on the Cone, Injector Seal D11.95MM 2072703140 (1b) mounted on the fuel injector.
Using the Installer, Injector Seal to Cone 2072702140 (2a), fit the back-up ring on the fuel injector (2b).

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Check that the NEW back-up ring is correctly fitted into the fuel injector with the Tool, Injector Seal Calibration D11.95MM 2072707140 (1). The tool has to run freely without skipping.

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Install a NEW O-ring in position (1a).
Remove the Clip, Fuel Injector 2072701140 and install the retaining clip (1b).

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Insert the injector seal (1a) on the Cone, Injector Seal D7.80MM 2072704140 (1b) mounted on the injector (1c).
Using the Installer, Injector Seal to Cone 2072702140 (2a), slide the injector seal into the recess on the fuel injector (2b).

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Size the injector seal by sliding the Tool, Injector Calibration D8.00MM 2072705140 (1b) onto the injector tip (1a).

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Check that the injector seal is correctly fitted onto the injector (1a) with the Tool, Injector Seal Calibration D7.80MM 2072706140 (1b). The tool has to install and remove freely without catching on the injector seal edge.
NOTE:
The Tool, Injector Calibration D8.00MM 2072705140 can be installed a second time if needed.
Repeat the rings and seals replacement for all of the other injectors.

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If removed, install the fuel rail pressure sensor (1a) and tighten to the proper torque specifications. Refer to FUEL DELIVERY, TECHNICAL SPECIFICATIONS .
Lightly lubricate NEW O-ring seals (1c) with engine oil and install the injectors (1b) in the fuel rail cups.

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The injector clip (1) must be in contact with the fuel rail cup.
Install and hand tighten the (special tool #2044400140, Guide, Fuel Rail Installer) on the cylinder head.

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Position the fuel injectors (1) 90 degrees (2) from the fuel rail center line.

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Align the fuel injector electrical connectors (1) with the slots in the cylinder head. DO NOT push the fuel rail into the cylinder head until the fuel injectors are aligned.

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NOTE:
Do not lubricate the new injector seals prior to installation into the cylinder head.
Install the fuel rail complete with injectors (1b). Remove the (special tool #2044400140, Guide, Fuel Rail Installer) from the cylinder head.
To avoid side loading damage, tighten the
NEW

bolts (1a) at the same time, or in alternating one half turn increments in two steps:
- Tight the two inner bolts and then the two outer bolts to an initial torque of 2.5 N.m (22 in. lb.).
- Tight the two inner bolts and then the two outer bolts to the proper torque specifications. Refer to FUEL DELIVERY, TECHNICAL SPECIFICATIONS .
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Connect and lock the injector wire harness connectors (1).
Engage the wire harness retaining clips to the fuel rail.
Connect and lock the fuel pressure sensor wire harness connector.
Connect the oil temperature sensor wire harness connector.
Connect the oil vapor line to cam cover.

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NOTE:
The high pressure fuel line can be reused if the injection pump and fuel rail are being reused, otherwise the high pressure fuel line must be discarded and replaced.
Lightly lubricate the fuel line nuts with clean engine oil.
Install the high pressure fuel line (2b) and tighten the nuts (1, 2a) to the proper torque specifications. Refer to FUEL DELIVERY, TECHNICAL SPECIFICATIONS .
Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
Check the high pressure fuel system for leaks. Refer to FUEL DELIVERY, DIAGNOSIS AND TESTING .