Fuel Injector: Service and Repair

REMOVAL PROCEDURE

CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions.

1. Relieve the fuel system pressure.

IMPORTANT: Mask off the intake ducts after removing the upper plenum. Entry of foreign objects can cause severe engine damage.

2. Remove the intake plenum.

NOTE: Refer to Removing Fuel Rail Assembly Notice in Service Precautions.

3. Disconnect the fuel rail intermediate lines, supply-return. Then position the fuel rail intermediate lines away from the fuel rail.
4. Remove the fuel rail bracket bolts near the fuel supply-return lines.
5. Disconnect the fuel injector electrical connectors. Unclip the harness from the fuel rail and position it out of the way.
6. Disconnect the fuel pressure regulators atmospheric vent hose.
7. Remove the fuel rail attaching bolts from the intake manifold.

CAUTION: Refer to Safety Glasses and Compressed Air Caution in Service Precautions.

8. Use compressed air in order to blow dirt out of the area where the injectors enter the intake casting.
9. Remove the fuel rail assembly.
10. Remove the retainers from the fuel injectors.
11. Remove the injectors from the fuel rail.

NOTE: If necessary, remove rust or burns from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

12. Remove the O-rings from the injectors. Discard the O-rings.

INSTALLATION PROCEDURE
1. Lubricate the new injector O-rings with clean engine oil.
2. Install the new injector O-rings on the injectors.
3. Install the injectors to the fuel rail with the new retainer clips.
4. Ensure that the injectors are aligned by orienting the electrical connectors perpendicular to the crankshaft centerline.
5. Install the fuel rail with the injectors to the intake manifold.
6. Install the fuel rail attaching bolts to the intake manifold.

Tighten
Tighten the fuel rail attaching bolts to 8 N.m (71 lb in).

7. Reconnect the fuel pressure regulators atmospheric vent hose.
8. Reconnect the fuel injector electrical connectors and the clip harness to the fuel rail.
9. Install the fuel rail bracket bolts near the fuel supply-return lines.

Tighten
Tighten the fuel rail bracket bolts to 8 N.m (71 lb in).

10. Reconnect the fuel rail intermediate lines, supply-return, to the fuel rail.

Tighten
Tighten the supply and return lines to 15 N.m (11 lb ft).

11. Reinstall the intake plenum.
12. Connect the negative battery cable.
13. Crank the engine for a few seconds. Turn OFF the engine if the engine starts.
14. Check for fuel leaks.