Removal and installation injectors (Mazda Familia BG)

Faulty injectors can cause severe engine detonation and damage to bearings. In this case, let the engine idle and loosen the union nuts of the injectors one by one. If the detonation disappears when one of the nuts is loosened, this indicates a faulty injector.



A faulty injector can also be identified by loosening the union nuts one by one while the engine is running at fast idle speed. If the speed remains the same after loosening one of the injectors, that injector is faulty. The injector can be checked with a pressure gauge. (This is done in a workshop.); required spray pressure: 110 Bar).

The first signs of injector failure:

• Ignition failures
• Detonation in one or more cylinders
• The engine gets very hot
• Engine power loss
• Excessively strong black exhaust cloud
• High fuel consumption

Removal

1. Disconnect the ground cable from the battery.

Warning! This will erase the engine fault memory or the radio security code. Before disconnecting the battery, read the instructions in Section Removal and installation the battery.

2. Unscrew the intake noise muffler and resonance channel.

3. Thoroughly clean the outside of the injection and return fuel lines with a cold cleaner.

4. Remove the injection pipes as a set; to do this, loosen the union nuts on the high-pressure fuel pump and injectors using a slotted open-end wrench.

Attention! Do not change the shape of the bend.

5. Remove the fuel hose from the return line and loosen the lock nut, remove the gaskets and return line.

6. Remove the injectors and arrange them in the order of installation.

Attention! No dirt should get into the combustion chambers through the nozzle holes.

7. In each hole there is also a gasket and a washer that must be replaced.

8. Check the injector needle for wear and damage, remove soot with a wooden spatula.

Attention! Never treat the nozzle or nozzle needle with wire, a file or sandpaper. Do not mix up individual elements of the nozzles.

Installation

1. Install 4 new gaskets and washers.

Attention! Observe the installation position, the blue mark must face up.

2. Install the injectors and tighten them with force 65 Nm.

Attention! Overtightening the injector holders may result in deformation of the injectors, jamming of the injector needles or other damage.

3. Install the fuel return line with new gaskets and tighten the nuts with force 30 Nm.

4. Install the injection pipes, tighten the union nuts with force 30 Nm.

5. On all injector holders, slightly loosen the union nuts of the injection pipes.

6. Turn the crankshaft with the starter until fuel comes out of the pipes. Tighten the pipes to the specified torque.

7. Install the intake noise muffler and resonance channel.



8. Connect the ground cable to the battery.

9. If available, set the time on the clock and set the security code for the radio receiver.