Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Installation Procedure
- Clean and inspect the fuel injectors and the fuel injector rail. Do not remove the fuel injector from the fuel rail. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection .
Install a NEW combustion fuel injector seal (1) to the EN-51146-2-2 mounting sleeve-long (2).
Use the EN-51146-2-6-1 slider outside (1) to push down the combustion fuel injector seal (2) on the EN-51146-2-2 mounting sleeve-long (3).
Push the combustion fuel injector seal (2) over the EN-51146-2-2 mounting sleeve-long, use the EN-51146-2-6-1 slider outside (1) to the fuel injector (3).
- Remove the EN-51146-2-2 mounting sleeve-long with the EN-51146-2-1 stylus from the EN-51146-2-6-1 slider outside.
- Install a NEW combustion fuel injector seal to the EN-51146-2-3 mounting sleeve-short.
- Use the EN-51146-2-6-1 slider outside to push down the combustion fuel injector seal on the EN-51146-2-2 mounting sleeve-short.
- Push the combustion fuel injector seal over the EN-51146-2-3 mounting sleeve-short, use the EN-51146-2-6-1 slider outside to the fuel injector.
- Remove the EN-51146-2-3 mounting sleeve-short with the EN-51146-2-1 stylus from the EN-51146-2-6-1 slider outside.
Before using the EN-51146-2-4 pre-sizing tool (1), check if the fuel injector limiter (2) is in the right position.
- NOTE:
First form the combustion fuel injector seals a bit with finger and thumb.
Push the EN-51146-2-4 pre-sizing tool (1) over the fuel injector (2).
Tighten the nut (2) and counterhold at the spanner flat of the EN-51146-2-4 pre-sizing tool thread (1) until the measure (a) of 4.5 mm (0.177 in) is reached.
- Loosen the nut (2) of the EN-51146-2-4 pre-sizing tool.
Install the EN-51146-2-4-7 take off chassis (2) to the EN-51146-2-4 pre-sizing tool (3).
- Install the EN-51146-2-4-6 screw M10 (1) to the EN-51146-2-4-7 take off chassis (2), and tighten until the EN-51146-2-4 pre-sizing tool (3) is loosened.
Install the EN-51146-2-5 calibration tool (2) to the fuel injector (1), as shown in the graphic.
- Remove the EN-51146-2-5 calibration tool from the fuel injector.
- WARNING:
The fuel injector seals must fit properly in the relative groove. Overlapping of the fuel injector seals with the external surface of the injector must be avoided. If the seals are installed incorrectly, it could cause leaks and risk of injury.
Check the combustion fuel injector seals (2 seals each fuel injector) for correct seat:
- The seal must not be too large, buckled or corrugated (1).
- The seal must be fixed tight and accurate (2).
- If the seals are installed incorrectly, repeat the steps 27 - 29 of the removal procedure and the steps 1 - 19 of the installation procedure.
Install the 4 EN-51146-2-5 calibration tools (2) to the fuel injectors (1).
- Remove the fuel injector assembly with the EN-51146-100 plate from the bench vise.
Remove the 8 plate bolts (1) and remove EN-51146-100 plate (2), counterhold with a wrench (4) at the EN-51146-1-1 supports (3).
Remove one EN-51146-1-1 support (2) from the fuel injector (3).
- Apply thread lock agent to the NEW fuel injector bolt (1).
- Install NEW fuel injector bolt to the fuel injector and tighten to 5 N.m (44 lb in).
Remove the EN-51146-1-1 support (1) from the fuel injector (3).
- Apply thread lock agent to the NEW fuel injector bolt (2). Adhesives, Fluids, Lubricants, and Sealers
- Install a NEW fuel injector bolt to the fuel injector and tighten to 5 N.m (44 lb in).
- Repeat the steps 22 - 27 for the other 3 injectors.
- Clean the fuel injector bores at the cylinder head. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection .
Inspect the fuel injector rail assembly:
- Check the 4 fuel injector for damage.
- Check the 8 fuel injector seals for correct seat.
- Check if all bolts (3) with decoupling elements (1) and retainer (2) are complete.
- Remove the 4 EN-51146-2-5 calibration tools from the fuel injector.
- CAUTION:
During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.
Install the fuel rail assembly (1).
- Push the fuel injectors slightly in their seats.
Tighten the 8 fuel rail bolts in the sequence as shown to 10 N.m (89 lb in).
Fuel Injection Fuel Rail Wiring Harness(1) - Connect
- Fuel Feed Intermediate Pipe Replacement - Install
- Ignition Coil Replacement - Install
Never loosen both EN-51146-1-1 supports at the same time. Failure to follow this caution could cause leaks or malfunction after installation. It is only possible, when the fuel injector will be replaced.
DO NOT reuse the old fuel injector bolt.
DO NOT reuse the old fuel injector bolt.
Fuel escapes - observe safety measures and national legislation. Failure to comply could result in personal injury.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.