Fuel Injector: Service and Repair

REMOVAL PROCEDURE

CAUTION: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.




1. Relieve the fuel system pressure. Refer to "Fuel Pump".
2. Disconnect the negative battery cable.
3. Disconnect the intake air temperature (IAT) sensor connector.
4. Disconnect the breather hose from the valve cover.




5. Remove the air intake tube.
6. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
7. Disconnect the throttle cables from the throttle body and bracket.
8. Remove the fuel pressure regulator. Refer to "Fuel Pressure Regulator".
9. Disconnect the fuel return line at the fuel rail.
10. Disconnect the fuel inlet line at the fuel rail.
11. Remove the fuel rail retaining bolts.





NOTE: Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and the injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service.

IMPORTANT: If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.

12. Remove the fuel rail with the fuel injector channel cover and the injectors attached.
13. Disconnect the fuel injector channel cover connectors.




14. Remove the fuel injector retainer clips.
15. Remove the fuel injectors by pulling them down and out.
16. Discard the fuel injector O-rings.

INSTALLATION PROCEDURE

IMPORTANT: Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.




1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
3. Install the fuel injector retaining clips onto the fuel injector and the fuel rail ledge.
4. Make sure that the retaining clip should be parallel to the fuel injector harness connector.




5. Install the fuel rail assembly into the cylinder head.
6. Install the fuel rail retaining bolts.

Tighten
Tighten the fuel rail retaining bolts to 25 Nm (18 lb-ft).




7. Connect the fuel inlet line to the fuel rail.
8. Connect the fuel return line to the fuel rail
9. Install the fuel pressure regulator. Refer to "Fuel Pressure Regulator".
10. Connect the fuel injector channel cover and connectors. Rotate each fuel injector as required.
11. Connect the throttle cables to the throttle body and bracket.
12. Connect the PCV hose to the valve cover.




13. Install the air intake tube.
14. Connect the breather hose to the valve cover.
15. Connect the IAT sensor connector.
16. Connect the negative battery cable.
17. Perform a leak check of the fuel rail and fuel injectors.