This procedure covers the removal and replacement of a single fuel injector on the 2.5L I4 engine, including fuel system depressurization and fuel rail removal.

Warnings

Tools required

Parts

• Fuel injector × 1 — Use OEM specification for 2.5L Smartstream engine
• Fuel injector O-ring kit × 1 — Upper and lower O-rings included
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Ensure engine is completely cool to touch
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge
4. Remove engine cover by pulling upward on cover - it is retained by rubber grommets
5. Place absorbent towels around fuel rail area to catch residual fuel

Procedure

1. 1

   Depressurize fuel system
   Locate the fuel pump relay in the engine bay fuse box (relay R15). Remove the fuel pump relay. Attempt to start the engine and let it run until it stalls from fuel starvation. Attempt to start 2-3 more times to ensure system is fully depressurized. Turn ignition OFF.
   ⚠️Do not skip this step. Pressurized fuel spray can cause fire or serious injury.
2. 2

   Disconnect electrical connectors
   Press down on the locking tab of each fuel injector electrical connector and pull straight up to disconnect. Disconnect all four injectors even if only replacing one - this provides better access. Mark the faulty injector position for reference.
   ⚠Do not pull on wires - always grasp the connector body to prevent wire damage.
3. 3

   Disconnect fuel supply line
   Using the appropriate fuel line disconnect tool, depress the release tabs on the quick-connect fitting at the fuel rail inlet. Pull the fuel line straight out from the fuel rail. Expect residual fuel to drain - use shop towels to contain spillage. Inspect the O-rings in the disconnected fitting and replace if damaged.
   ⚠Residual fuel will drain from the line. Have towels ready and avoid fuel contact with skin.
4. 4

   Remove fuel rail mounting bolts
   Locate the two fuel rail mounting bolts securing the rail to the cylinder head. Using a 10mm socket, remove both fuel rail mounting bolts completely. Keep bolts organized for reinstallation.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
5. 5

   Remove fuel rail assembly
   Carefully pull the entire fuel rail assembly straight upward with even pressure. The injectors will pull out of their bores in the intake manifold. Rock gently side-to-side if resistance is encountered, but do not pry. Once free, place the fuel rail assembly on a clean work surface.
   ⚠Do not damage injector tips or spray patterns. Keep assembly clean and away from dirt or debris.
6. 6

   Remove faulty fuel injector
   Locate the injector to be replaced. Slide the retaining clip off the fuel rail where it secures the injector. Pull the injector straight out of the fuel rail socket. Note the orientation and position of the upper and lower O-rings on the old injector.
   ℹ️Retaining clips are under spring tension. Control them carefully to prevent loss.
7. 7

   Prepare new fuel injector
   Remove old O-rings from the fuel rail bore if they remained in place. Lubricate the new upper and lower O-rings (included with new injector or in O-ring kit) with clean engine oil. Install both O-rings onto the new injector, ensuring they are properly seated in their grooves. Verify the injector screen/filter is clean and properly installed.
   ⚠Never reuse old O-rings. Always use new O-rings to prevent fuel leaks.
8. 8

   Install new fuel injector
   Insert the new injector into the fuel rail socket, aligning it properly with the bore. Push firmly until it seats completely. Install the retaining clip by sliding it over the injector and fuel rail junction until it clicks into place. Verify the clip is fully engaged and the injector cannot be pulled out.
   ℹ️Ensure injector electrical connector faces the correct direction for reconnection before securing clip.
9. 9

   Install fuel rail assembly
   Inspect all injector lower O-rings and the intake manifold injector bores - clean any debris. Align all four injectors with their respective bores in the intake manifold. Apply even downward pressure to seat all injectors simultaneously. Press firmly until the fuel rail mounting surfaces contact the cylinder head.
   ⚠Ensure all injectors enter their bores squarely. Cocked injectors can damage O-rings or injector tips.
10. 10

    Install fuel rail mounting bolts
    Thread both fuel rail mounting bolts by hand to prevent cross-threading. Tighten bolts in an alternating pattern using a torque wrench to the specified torque of 12.0 Nm (9.0 lb-ft).
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect fuel supply line
    Install new O-rings onto the fuel supply line quick-connect fitting if they were damaged or removed. Push the fuel line straight onto the fuel rail fitting until it clicks and locks into place. Tug gently on the line to verify it is fully engaged and locked.
    ℹ️The connection should click audibly when fully seated. If no click is heard, remove and reinstall.
12. 12

    Reconnect electrical connectors
    Reconnect each fuel injector electrical connector by aligning and pressing down firmly until the locking tab clicks. Verify each connection by gently pulling on the connector - it should not come off.
    ℹ️Ensure connectors are fully seated to prevent misfires or injector codes.
13. 13

    Reinstall fuel pump relay and check for leaks
    Reinstall the fuel pump relay (R15) in the engine bay fuse box. Reconnect the negative battery terminal. Turn the ignition to ON position (do not start engine) for 5 seconds, then OFF. Repeat this cycle 3 times to prime the fuel system. Inspect all fuel connections, injector O-ring areas, and the fuel rail for any signs of fuel leakage.
    ⚠️If any fuel leaks are detected, immediately turn off ignition and repair the leak before proceeding.

Reassembly

1. Install engine cover by aligning grommets with mounting posts and pressing down firmly until seated
2. Clear any diagnostic trouble codes using an OBD-II scanner if warning lights are illuminated
3. Dispose of old fuel injector and contaminated shop towels properly according to local regulations

Verification

• Start the engine and let it idle for 2-3 minutes while monitoring for fuel leaks around all connections and injector seals
• Check for smooth idle and absence of misfires - engine should run smoothly without hesitation
• Verify no fuel odor is present in engine bay or cabin
• Test drive vehicle and confirm normal acceleration and no diagnostic trouble codes
• Recheck all fuel connections after test drive for any delayed seepage

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