Fuel Injector: Service and Repair

Direct Fuel Injector Replacement

Special Tools
* J-2619-01 - Slide Hammer
* J-37281-A - Injector Remover

Removal Procedure




1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
2. Remove the intake manifold assembly. Refer to Intake Manifold Replacement (Service and Repair).




3. Remove the fuel injector insulator.




4. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (High Pressure Side) (Fuel Pressure Relief (High Pressure Side)).
5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
6. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
7. Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement (Fuel Feed Intermediate Pipe Replacement).




8. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
9. Remove the fuel rail bolts (1).

Note: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail.

10. Carefully remove the fuel rail (2).




11. Remove and discard the direct fuel injector hold down clamps.




12. Remove the direct fuel injectors.





Note: A fuel injector may remain stuck in the cylinder head. If this occurs, complete the following steps:

1. Remove the fuel injector hold-down clamp before removing the fuel injector.
Note: Use the injector remover and slide hammer to pull the fuel injector straight out along the fuel injector axis. DO NOT tilt or twist the fuel injector during this process.

2. Use J-37281-A - injector remover , and J-2619-01 - hammer to remove the fuel injector.
3. Once injectors have been removed it will be necessary to clean and rebuild all the injectors. Refer to Fuel Rail and Injectors Cleaning and Inspection (47. Fuel Rail and Injectors Cleaning and Inspection).

Installation Procedure




1. Install the 2 outer fuel rail bolts (1) first, hand tight and install the remaining 2 bolts, hand tight.
2. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Tighten the fuel rail bolts in the sequence shown.

1. Tighten the bolts a first pass to 22 Nm (16 lb ft).
2. Tighten the bolts a final pass to 22 Nm (16 lb ft).

4. Install the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement (Fuel Feed Intermediate Pipe Replacement).




5. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
6. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.




7. Install the fuel injector insulator.




8. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
9. Inspect for leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

10. Install the low side fuel pressure service port cap.
11. Tighten the fuel fill cap.
12. Install the intake manifold assembly. Refer to Intake Manifold Replacement (Service and Repair).