Fuel Injector: Service and Repair

REMOVAL PROCEDURE

CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.

After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the fuel rail.
4. Remove the fuel injector retaining clip (2).
5. Remove the fuel injector (3).

INSTALLATION PROCEDURE

IMPORTANT: Each fuel injector is calibrated for a specific flow rate. When replacing fuel injectors, be sure to order the correct fuel injector for the application being serviced.

1. Lubricate new fuel injector O-ring seals (1,4,5) with clean engine oil, and install on the fuel injector assembly (3).

IMPORTANT: When installing the fuel injector, care should be taken not to tear or misalign the fuel injector O-rings.

2. Install the fuel injector upper O-ring (1).
3. Install the fuel injector lower back-up O-ring (4).
4. Install the fuel injector lower O-ring (5).
5. Install the fuel injector (3) to the fuel rail.
6. Install the fuel injector retaining clip (2).
7. Install the fuel rail.
8. Connect the negative battery cable.
9. Inspect for leaks through the following steps:
9.1. Turn ON the ignition for two seconds.
9.2. Turn OFF the ignition for ten seconds.
9.3. Turn ON the ignition.
9.4. Check for fuel leaks.