Fuel Injector: Service and Repair

WARNING: Do not smoke while working on the fuel system. Keep open flames or sparks away from the work area. Make sure engine is OFF while relieving fuel pressure.

Loosen The Service Bolt:

1. Relieve the fuel pressure.
a. Disconnect the negative battery cable (retain code for radio first).
b. Remove the Fuel Tank Filler Cap.
c. Use a box end wrench on the 6mm service bolt at the top of the Fuel Filter, while holding the special banjo bolt with another wrench.
2. Disconnect the 2P connectors from the Fuel Injectors.
3. Disconnect the vacuum hose and fuel return hose from the Fuel Pressure Regulator.

NOTE: Place a rag or shop towel over the hoses before disconnecting them.

Fuel Injector Replacement:

4. Disconnect the fuel hose and the Fuel Pulsation Damper from the Fuel Rail.
5. Loosen the retainer nuts on the Fuel Rail and harness holder, disconnect the Fuel Rail.
6. Remove the injectors from the Intake Manifold.
7. Slide new cushion rings onto the Injectors.
8. Coat new O-rings with clean engine oil and put them on the Injectors. Insert the Injectors into the Fuel Rail first.

Fuel Injector Installation:

9. Coat new seal rings with clean engine oil and press them into the Intake Manifold, install the Injectors and Fuel Rail assembly in the manifold.

NOTE: To prevent damage to the O-ring, install the Fuel Injectors in the Fuel Pipe first, then install them in the Intake Manifold.

10. Install and tighten the retainer nuts.
11. Connect the fuel hose and the Fuel Pulsation Damper to the Fuel Rail with new washers, then connect the vacuum hose and fuel return hose to the Fuel Pressure Regulator.
12. Install the 2P connector on the Injectors, replace the 6mm service bolt washer and tighten the bolt.
13. Turn the Ignition Switch ON but do not operate the Starter. After the Fuel Pump runs for approximately two seconds, the fuel pressure in the fuel line rises. Repeat this two or three times, then check whether there is any fuel leakage.