MrG 3 Posted February 21, 2008 Is this an easy job? Its a bit sketchy in the haynes manual I have. Share this post Link to post Share on other sites
DrSarty 90 1 Cars Posted February 21, 2008 (edited) Is this an easy job? It's a doddle...BUT, the fuel rail (the metal tube they all fit into) is always under pressure. I would advise unbolting the whole rail from the head and pull all the injectors at once from the head, still connected to the rail. Then it's just a matter of undoing the metal retaining clips, one on the injector itself and one on the plug connector and pulling the plug out from the rail. BEWARE though, the first one out will release fuel under pressure, and it can - like it did with me once - spray in your eyes. Not funny at all. Edited February 21, 2008 by DrSarty Share this post Link to post Share on other sites
davemar 16 Posted February 21, 2008 There's not a huge amount to do, but it can be awkward as they get stiff. The way I do it is to gradually lever out the whole injector rail with the injectors still attached to it from the manifold. You'll have to lever each injector a little at a time from the manifold to try and bring the whole thing away without putting to much stress on things. To remove the injectors from the rail you need to remove the clips that hold them on (just ping them off with a screwdriver), and then carefully lever each one out. I found refitting the injectors into the rail more awkward as the rings are difficult to push home. The method I used was to place a socket over the end of each injector so that it is pushing down on its shoulder; and then use a large clamp (B&Q sell these trigger style clamps which are good for this) around the socket and rail to squeeze the injector in. One they are all back in the rail (don't forget the clips) it is easy enough to fit them to the manifold as when you screw it down the injectors are pushed home. Share this post Link to post Share on other sites
VisaGTi16v 1 Posted February 21, 2008 Don't smoke whilst doing it Share this post Link to post Share on other sites
davemar 16 Posted February 21, 2008 Just to add to DrSarty comments about the fuel, it's probably a good idea to detach on the fuel hoses on the rail to relieve the fuel pressure. Get a jar ready and hold it away from you and wear gloves if possible. It'll spurt out a good 'un to start with, but it's better to do it in this controlled way rather than when you're trying to fiddle around with the injectors. You could always run the engine and disconnect the fuel pump (under the rear seat) until it stalls to relieve some of the pressure too. Share this post Link to post Share on other sites
welshpug 1,657 Posted February 21, 2008 easy peasy way to sort the fuel pressure issue. Pull fuse 15, the closest one on the fusebox to the driver, and start it, when it stalls proceed with the removal Share this post Link to post Share on other sites
MrG 3 Posted February 21, 2008 cheers all, I will have a go over the weekend. Gloved, glassed and fag out to be sure. Share this post Link to post Share on other sites
steve@cornwall 100 Posted February 21, 2008 An open end spanner (19mm IIRC) makes an ideal gentle lever between the injector and head. Release the rail (remove the 4 10m bolts) then gently ease the injectors out, starting at one end. Share this post Link to post Share on other sites
paulh 0 Posted February 21, 2008 Pull fuse 15, the closest one on the fusebox to the driver, and start it, when it stalls proceed with the removal Thats just what I do, but I thought the fuel pump was fuse 14. I could be wrong though Share this post Link to post Share on other sites
KRISKARRERA 2 1 Cars Posted February 21, 2008 Mine were stuck in like concrete. Where's the best place to get new O rings? Share this post Link to post Share on other sites
MrG 3 Posted February 22, 2008 Dealers maybe? Or ebay? I bought a kit from ebay and it appears ok? Share this post Link to post Share on other sites
welshpug 1,657 Posted February 22, 2008 Dealers want quite a bit of money, best bet is a Bosch agent. Share this post Link to post Share on other sites
DrSarty 90 1 Cars Posted February 22, 2008 (edited) 'O' Rings R Us? Edited February 22, 2008 by DrSarty Share this post Link to post Share on other sites
mikebullock84 0 Posted May 15, 2008 *bump* im currently ugrading the engine on mine, but with beginners haste, i have taken the injector plug connectors off the relevant injectors! doh! so i dont know which ones plug back where! Surely someone has done this before!?! who can tell me which plug goes on which?! cheers in advance! Share this post Link to post Share on other sites
welshpug 1,657 Posted May 15, 2008 which engine management system is it? most older pugs run batch fired injection which means all injectors fire at once Share this post Link to post Share on other sites
mikebullock84 0 Posted May 15, 2008 um? not sure monotronic? its f reg 1988 1.9, thanks for the quick reply Share this post Link to post Share on other sites
welshpug 1,657 Posted May 15, 2008 Jetronic 8 valve? doesn't matter which one if it is then. Share this post Link to post Share on other sites
mikebullock84 0 Posted May 15, 2008 oh great thats a relief then, should be pretty striaght forward when i put the motor back in then, cheers mate. fingers crossed the dimma will be on the road in 4 weeks, thanks again! Share this post Link to post Share on other sites
