Fuel injector (1.6 and 1.8 litre (R6A type) CVH) - removal and refitting

Caution: Refer to the precautions in Section 1 before proceeding.

1.6 litre
Note: New fuel injector seals must be used on refitting.

1 Disconnect the battery negative lead.

2 Remove the air cleaner.

3 Depressurise the fuel system.

4 Release the securing lugs, and disconnect the fuel injector wiring plug (see illustration).

16.4 Disconnecting the fuel injector wiring plug
16.4 Disconnecting the fuel injector wiring plug

5 Bend back the injector retaining collar securing bolt locktabs, then unscrew the bolts. Remove the injector retaining collar (see illustrations).

16.5a Removing an injector retaining collar securing bolt and locktab
16.5a Removing an injector retaining collar securing bolt and locktab

16.5b Removing the injector retaining collar
16.5b Removing the injector retaining collar

6 Withdraw the injector from the CFI unit (see illustration), noting its orientation, then withdraw the injector seals.

16.6 Withdrawing the fuel injector
16.6 Withdrawing the fuel injector

7 Remove the seal from the injector retaining collar (see illustration).

16.7 Removing the seal from the injector retaining collar
16.7 Removing the seal from the injector retaining collar

8 Refitting is a reversal of removal, noting the following points.

9 Use new injector seals, and lubricate them with clean engine oil before fitting.

10 Ensure that the locating peg on the injector is correctly positioned (see illustration).

16.10 Align locating peg on injector with slot in CFI unit on refitting - 1.6
16.10 Align locating peg on injector with slot in CFI unit on refitting - 1.6 litre CVH

1.8 litre
11 On these engines, the fuel pressure regulator and injector are one assembly.

Proceed as described for the fuel pressure regulator.

Fuel injector ballast resistor (1.6 litre CVH) - removal and refitting

1 The ballast resistor is located on the righthand side of the engine compartment, and is only fitted to 1.6 litre engines (see illustration).

17.1 Fuel injector ballast resistor location (arrowed)
17.1 Fuel injector ballast resistor location (arrowed)

2 Disconnect the battery negative lead.

3 Disconnect the ballast resistor wiring connector, then remove the securing screw, and withdraw the ballast resistor from the body panel.

4 Refitting is a reversal of removal.

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