Fuel injectors

Operation 1060F10 · Injectors and lines

1.9 JTD 8v

Removing

- 1016A10 sound-proofing cover - r + r

- 1060F36 lines to injectors - r r

Disconnect the pipe from the injectors to the fuel recovery manifold from the manifold and injectors.

Disconnect the injector electrical connections

1. Undo the injector anchoring brackets securing nuts.

2. Fit injector removal device (2a). Ensure lifting bracket (2b) is fitted beneath the polygonal area of the injector.

3. Fit the second lifting bracket (3a) of the device under injector securing bracket (3b).

4. Tighten device nut (4a) and remove the injector (4b).

Repeat the operation for the remaining injectors.

1.9 JTD 16v

Removing

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Disconnect the battery negative terminal.

1. Disconnect the electrical connections from the injectors.

2. Disconnect the electrical connection from the cam angle sensor.

3. Disconnect the electrical connection for the air conditioning compressor electromagnet coupling.

Undo the earth lead on the air conditioner compressor.

Release the electrical wiring from the band on the timing cover.

4. Undo the bolts fastening the cable duct and move the electrical wiring aside.

1.9 JTD 8v

Refitting

Check the injectors are in good condition.

The modification will be implemented from October 2001 from engine no. 2805542.

If a premodification engine injector is replaced, fit parts marked with the code C5603 and do not work on the injection control unit.

When replacing post-modification injectors, order parts identified as D5303 and no. 73501139. These parts are category 2C and require a specific injection control unit customisation procedure. This procedure is carried out using an Examiner diagostic tester and using the controls in the active Injector Classification function.

Fit the injectors complete with bracket.

Tighten the fixing nuts to torque.

Fit the injection wiring and tighten the fixing bolts.

Connect the electrical connections to the injectors.

Connect the pipe clips to the injectors and connect the pipe to the return manifold.

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- 1016A10 sound-proofing cover - r + r

1.9 JTD 16v

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.

Start removal beginning with the fuel injector of cylinder no. 1 and continuing with the injectors for cylinders 2, 3 and 4.

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.

1. Fit new pipes from the fuel manifold to the injectors and fix 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.

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.

Clean the threaded seats for the above-mentioned pipe on the manifold and the injectors using heptane.

Connect the pipe from the injectors to the fuel recovery manifold to the injectors pushing it until the clips can be heard clicking into place.

Place the electrical wiring back in its housing and tighten the cable duct fixing bolts.

Connect the electrical connections to the injectors.

Connect the timing sensor electrical connection.

Connect the electrical connection to the air conditioning compressor electromagnet coupling.

Tighten the earth lead nut to the air conditioner compressor.

Connect the negative (-) battery terminal

- 1016A10 sound-proofing cover - r + r.