Fuel Injector: Service and Repair

Each fuel injector is serviced as a complete assembly only.

NOTICE:
- Use care in removing injectors to prevent damage to the electrical connector terminals, the injector filter, and the fuel nozzle. Also, since the injectors are electrical components, they should not be immersed in any liquid solvent or cleaner as damage may occur.








REMOVAL
1. Negative battery cable
2. Relieve fuel system pressure. (Refer to "Fuel Pressure Relief Procedure".)
3. Air cleaner assembly.
4. Electrical connectors to fuel injector. (Squeeze plastic tabs and pull straight up.)
5. Fuel meter cover attaching screws (1, 2).
6. Fuel meter cover assembly (3).
7. Fuel meter outlet passage gasket (5) and Fuel pressure control valve dust seal (6). If fuel meter cover gasket (4) stuck to fuel meter body, leave it in place. If it stuck to fuel meter cover, remove it, and place it on the fuel meter body.
- The fuel meter cover gasket will be used to protect the fuel meter body in the next step.
8. With fuel meter cover gasket on fuel meter body, use a screwdriver and fulcrum to carefully pry out injector (10).
9. Lower (small) 0-ring (12) form nozzle end of injector and discard.
10. Fuel meter cover gasket (4) and discard.
11. Upper (large) 0-ring (13) from top of injector cavity. Discard 0-ring.

INSPECTION AND REPAIR
- Fuel injector filter (11) for evidence of dirt and contamination. If present, check for presence of dirt in fuel lines and fuel tank.

CAUTION:
- When installing an injector, install the upper 0- ring before the injector, to ensure proper seating of the 0-ring. Reversing these steps could result in a fuel leak and possible fire.

INSTALLATION
1. Lubricate new upper (large) 0-ring (13) with engine oil, and install in fuel meter body cavity.
- Be sure 0-ring is seated properly, and is flush with top of fuel meter body surface.
2. Lubricate new lower (small) 0-ring (12) with engine oil, and install on nozzle end of injector.
- Push 0-ring on far enough to contact filter.
3. Fuel injector (10):




a. Align raised lug on injector base with notch in fuel meter body cavity.
b. Push down on injector until it is fully seated in fuel meter body. (Electrical terminals of injector should be parallel with throttle shaft.)
4. New pressure regulator dust seal (6), fuel meter outlet gasket (5), and cover gasket (4).
5. Fuel meter cover assembly (3).

IMPORTANT:
- If the fuel meter cover is removed for service, Loctite 262 or equivalent must be applied to the screw threads of the attaching screws before reinstalling.

6. Fuel meter cover attaching screws (1, 2) coated with appropriate thread-locking compound.

Tighten
- Fuel meter cover attaching screws to 3.0 N.m (27 lb.in.).

7. Electrical connectors to fuel injectors.
8. Tighten fuel filler cap.
9. Negative battery cable.

INSPECTION AND REPAIR
- Turn ignition switch to "ON" position for two seconds, then turn to "OFF" position for ten seconds. Again turn switch to "ON" position, and check for fuel leaks.

10. Air Cleaner Assembly.