Fuel Injector: Service and Repair

WARNING: Do not smoke during this repair. Keep open flames away from your work area. Be sure to relieve fuel pressure while engine is off. Place a rag or shop towel over the fuel hoses before disconnecting them.

DISASSEMBLY

Fuel System Service Bolt:

1. Relieve fuel pressure from system.
^ Disconnect the negative battery cable.
^ Remove the fuel tank filler cap.
^ 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.
^ Place a rag or shop towel over the 6mm service bolt and SLOWLY loosen the 6mm service bolt one complete turn.
2. Disconnect the electrical connectors from the injectors.
3. Disconnect the vacuum hose and fuel return hose from the pressure regulator.
4. Disconnect the fuel hose from the fuel pipe.
5. If needed remove the Idle Air Control (IAC) Valve from the intake manifold.
6. Loosen the retainer nuts on the fuel rail and harness holder.
7. Disconnect the fuel rail and PCV valve.
8. Remove the injectors from the intake manifold.

ASSEMBLY

Injector Seals, Cushion And Insulator Installation:

1. Slide new cushion rings onto the injectors.
2. Coat new O-rings with clean engine oil and put them on the injectors.
3. Insert the injectors into the fuel pipe first.
4. Coat the new seal rings with clean engine oil and press them into the intake manifold.
5. Install the injectors and fuel pipe assembly in the manifold. To prevent damage to the O-ring, install the injectors in the fuel pipe first, then install them into the intake manifold.

Installing Fuel Pipe And Injectors:

Alignment Marks For Injector And Fuel Pipe:

6. Align the center line on the injector with the mark on the fuel pipe.
7. Install and tighten the retainer nuts.
8. If removed, reinstall IAC Valve.
9. Connect the vacuum hose and fuel return hose to the pressure regulator.
10. Connect the hose to the fuel pipe and tighten the retainer nut to 22 Nm (16 ft.lb.)
11. Install the electrical connectors to the injectors.
12. Turn the ignition switch ON but do not attempt to start the engine. After the fuel pump runs for approximately two seconds, the fuel pressure rises. Repeat two or three times, then check for fuel leaks.