Fuel injectors
- Make
- Alfa Romeo
- Model
- GT Factory Service Manual
- Year
- 2003–2010
- Section
- Diesel injection system › Fuel injectors
FUEL INJECTORS
Removing
Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).
| Name | Connector | |
|---|---|---|
| Battery | See A1B BATTERY ( BATTERY NEGATIVE ) |
Proceed with removal
- 1016A10 sound-proofing cover - r + r
1. Disconnect the electrical connections from the injectors.
2. Disconnect the electrical connection from the cam angle sensor.
| Name | Connector | |
|---|---|---|
| 1 | Injector | See N70 INJECTOR |
3. Disconnect the electrical connection for the air conditioning compressor.
| Name | Connector | |
|---|---|---|
| 2 | Timing sensor. | See K47 TIMING SENSOR. ( CONNECTORS ) |
Release the electrical wiring from the band on the timing cover.
| Name | Connector | |
|---|---|---|
| 3 | Air conditioning compressor engagement electro-magnet | See L20 AIR CONDITIONING COMPRESSOR ENGAGEMENT ELECTRO-MAGNET ( CONNECTORS ) |
4. Undo the bolts fastening the cable duct and move the electrical wiring aside.
1. Push clips (1a) by hand and disconnect the pipe from the injectors to the fuel recovery manifold (1b), injectors side and move it aside.
2. Undo the connectors (2a), (2b) and remove the pipe from the fuel manifold to the injectors (2c).
Use new pipes from from fuel manifold to injectors upon reassembly.
1. Undo the nuts fixing the injector brackets.
2. Remove the injectors (2a) complete with bracket using the tool (2b).
If the same injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted.
If new fuel injectors are fitted:
determine the identification code stamped on the top;
check that the new injectors(s) is (are) recognized by the engine management control unit using the Examiner.
Start removal beginning with the fuel injector of cylinder no. 1 and continuing with the injectors for cylinders 2, 3 and 4.
| Name | Country | |
|---|---|---|
| 2b | Extractor | 1.870.897.300 |
Refitting
1. Refit the injectors (1a) complete with brackets and secure by tightening the nuts (1b) to the specified torque.
Start the refitting beginning with the injector for cylinder no. 4 and continuing with the injectors for cylinders 3, 2 and 1.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 1b | Nut | INJECTORS(DIESEL) | M8 | (Camshaft housing side 23 28 |
1. Fit the new pipes from the fuel manifold to the injectors and secure them using the connectors without tightening them.
2. Tighten the connectors for the pipes from the fuel manifold to the injectors, injector side, to the recommended torque using a suitable spanner.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 2 | Connector | FUEL MANIFOLD LINE TO INJECTORS | M12 | (Injector side 22 24 |
3. Tighten the connectors for the pipes between the fuel manifold and the injectors, fuel manifold side, to the recommended torque using a suitable spanner.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 3 | Connector | FUEL MANIFOLD LINE TO INJECTORS | M12 | Fuel manifold side 22 24 |
Clean the threaded seats for the above-mentioned pipe on the manifold and the injectors using heptane.
4. Connect the pipe from the injectors to the fuel recovery manifold (4a) to the injectors pushing it until the clips (4b) can be heard clicking into place.
Place the electrical wiring back in its housing and tighten the cable duct fixing bolts.
Fasten the electrical wiring using the band on the timing cover.
Connect the electrical connection to the air conditioner compressor.
Connect the electrical connection to the cam angle sensor
Connect the electrical connections to the injectors.
Proceed with refitting
- 1016A10 sound-proofing cover - r + r
Connect the negative (-) battery terminal
Parts & tools for this job For 2003 Alfa Romeo GT
- PARTFuel filterSearch: Alfa Romeo GT 2003 fuel filter
- TOOLFuel pressure test kitSearch: fuel pressure test kit
- TOOLFuel line disconnect toolSearch: fuel line disconnect tool
Links open Amazon search results in a new tab. As an Amazon Associate I earn from qualifying purchases.