Fuel Injector: Service and Repair
REMOVAL1. Remove throttle body.
NOTE: Prior to fuel injection supply manifold removal perform the following steps:
^ Scribe an alignment mark on base of distributor and lower intake manifold.
^ Remove distributor hold-down bolt.
^ Lift distributor enough to allow fuel injection supply manifold crossover tube to clear distributor housing and lower intake manifold.
2. Disconnect spring lock coupling fuel supply and fuel return lines.
3. Carefully disconnect wiring harness from fuel injectors.
4. Disconnect vacuum line from fuel pressure regulator.
5. Remove four fuel injection supply manifold retaining bolts (two on each side).
6. Carefully disengage fuel injection supply manifold assembly from fuel injectors by lifting and gently rocking the rail.
CAUTION: Fuel Injectors and fuel injection supply manifold must be handled with extreme care to prevent damage to sealing areas and sensitive fuel metering orifices.
7. Remove fuel injectors by lifting while gently rocking side to side.
INSTALLATION
1. Examine fuel injector O-rings for deterioration. Install new O-rings.
NOTE: When installing the fuel injection supply manifold with new or used injectors, particular attention should be paid to proper O-ring seating to ensure that no fuel leaks exist.
2. Lubricate new O-rings and install two on each fuel injector using clean engine oil XO-10W30-QSP (ESE-M2C153-E) or equivalent.
3. Ensure injector cups are clean and free of contamination or damage.
4. Install fuel injectors in fuel injection supply manifold using light twisting-pushing motion.
NOTE: Prior to installation perform the following steps:
^ Lift distributor enough to allow fuel injection supply manifold crossover tube to clear distributor housing and lower intake manifold and position fuel injection supply manifold.
^ Lower distributor into position.
^ Install distributor hold-down bolt and align scribe marks. Tighten hold-down bolt to 23-34 Nm (17-25 lb ft).
5. Carefully install fuel injection supply manifold assembly and fuel injectors into lower intake manifold, one side at a time. To ensure that O-rings are seated, push down on fuel injection supply manifold.
6. While holding fuel injection supply manifold in place, install four retaining bolts and tighten to 8-12 Nm (71-106 lb in).
7. Connect spring lock coupling fuel supply (1/2 inch) and fuel return (3/8 inch) lines.
8. Before connecting the fuel charging wiring harness, turn the ignition switch to the ON position several times. This will pressurize the fuel system.
9. Using a clean paper towel, check for leaks where the fuel injectors connect to the fuel injection supply manifold. If leaks are detected, service as required.
10. Connect the fuel charging wiring harness to the fuel injectors.
11. Connect vacuum line to fuel pressure regulator.
12. Install throttle body.