Fuel Injector: Service and Repair

REMOVAL
1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure.
2. Disconnect negative cable to battery.
3. Remove intake manifold plenum. Refer to the Engine section for information.
4. Remove intake manifold plenum mounting bolts. Lift Plenum up off of engine. Cover intake manifold to prevent foreign material from entering engine.
5. Disconnect fuel supply tube quick connect fittings at the rear of intake manifold. Refer to Quick Connect Fittings in the Fuel Delivery Section.
6. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder
7. Remove electrical connectors from the fuel injectors.
8. Remove fuel rail mounting bolts.
9. Lift fuel rail straight up off of the cylinder head.
10. Remove retaining clips from fuel injectors at fuel rail.
11. Remove fuel injectors.
12. Repeat for remaining injectors.
13. Check injector O-ring for damage. If O-ring is damaged, it must be replaced. Replace the injector clip if it is damaged.

INSTALLATION
1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
2. Install fuel injectors.
3. Install retaining clips on fuel injectors.
4. Push injectors into fuel injector rail until clips are in the correct position.
5. Position fuel rail over cylinder head, and push rail into place. Tighten fuel rail mounting bolts to 11 Nm (100 in. lbs.) torque.
6. Connect fuel supply tube quick connect fittings at the rear of intake manifold. Refer to Quick Connect Fittings in the Fuel Delivery Section.
7. Connect electrical connectors to fuel injectors.
8. Install intake manifold plenum. Refer to the Engine section for information.
9. Connect negative cable to battery.