Dear FIAT Stilo Gurus!

I need your help once more - I have to check the injectors in my 2002 Fiat Stilo 1.6 16V Dynamic, because @ the D81 connector one showed infinite resistance. That's why I need access to the injectors.

So right now my actual status:
- I removed big plastic air chamber, removed the two T30 size torx screws holding down the fuel rail, and it is free in theory. The problem is, that I have no idea about the next step - so how exactly should I remove the single fuel manifold (fuel rail) with the 4 injectors on it... The big metal inlet manifold is still in its place and because of that there is not much space left between the cylinder head and the metal inlet manifold for squeezing out the fuel rail + injectors... I tried to "grab" the fuel rail at around the valve (gearbox side) and at around the fuel in line connection part (timing belt side) and pull the whole thing, but no luck, and I am scared, I don't want to screw this one up.

Please some of you who actually had been able to achieve this task reply to this message and help me with some useful advice!

Thank you very much in advance!

The fuel injectors have an o ring seal at nozzle end and push fit into inlet manifold.
At the fuel rail the injectors should be held to the rail by 1 clip each.
If there is enough room pull the fuel rail and injectors should pull out of inlet manifold.
Good luck

Thx Jack, You are awesome!

So, fuel rail + injectors are finally free, but I have new questions!

First one is I think very important: I am trying not to let and drop any gunk or oily stuff, dust into those "glory holes", but the problem is that where the fuel rail sits, that place is full of black, sticky, gunky, crap - and when I was finally able to pull out the whole thing, all the injector's bodies were covered with this crapy stuff. Should I try to clean that place - I think I should, but how can I prevent any junk falling inside?

Second thing: I bought from eBay a used fuel rail with 4 working injectors. Those parts are nice and clean, all the injector's showing right resistance values etc. Should I change all the available parts, or I shouldn't bother with any of this, just clean my original parts (fuel rail + 3 injectors), and swap the dead one to a another one from the eBay purchase - does it matter which one? Should I stay with number 4?

Third thing: Do you have any other advice related to the injector pulling out and then putting back in sort of procedures?

Hi,
well done getting fuel rail and injectors out without removing inlet manifold.
Don't clean thats black and gunky there is too much danger or dirt going into inlet manifold through injector holes.

Did you have a faulty injector or faulty wiring ?

Your can use any injector for any cylinder on your engine without causing any problems.

(Common rail diesel engines injectors are the ones that you have to keep to original cylinder)

When refitting injectors and fuel rail make sure the o ring seal on end of each injector is good condition . Put a little engine oil on each o ring, the oil will make pushing the injectors into their holes much easier.
Don't drop any dirt into inlet manifold or get dirt on end of injectors.

Check injector wires wires resistance before putting it attached back together.

Thx once more Jack!

I did everything, changed injectors at cylinder 1 and 4, checked wires, then reassembled the whole engine and... no misfiring... XD I am happy as a bunny. Thx Jack, You helped me keep my faith in this funny little car.

Wires were faultless, injector 4 were totally dead (infinite resistance, soaked in petrol), injector 1 had around 20 Ohms, and also in February there was a p0201 error code, so changed that as well. I was very cautious, cleaned the injectors with toothbrush and with a clean, non dissolving cloth, and then started the whole process in the opposite order

Car started for the first time, after tiny bit more cranking than usual, but was ticking over nicely, I did let it run for a few minutes.

Next thing is going to be TB cleaning, and changing the stupid before CAT O2 sensor... Thank You Jack, You are a hero!

Hi,
just read your posts that you have succeeded , yey huge well done.
I know you were not comfortable with work needed to access injectors and I pushed you to do it.
Give yourself a big reward for not giving up.
It is unusual for an injector to fail is what most people say but you have proved it can happen so should be checked, that should help others in the future.

Your stilo must be much quicker with all four cylinders working and use less fuel?

It is surprising your ECU never gave a failed injector number 4 code.
Even more unusual is infinite resistance plus stuck open.

If you do need to change O2 sensor buy a proper branded one the cheaper Chinese ones are bad and cause problems without setting fault codes.

Your thanks to me are very much appreciated ?