Fuel Injector(s) Replacement

Upper And Lower Manifold Assemblies:

Injector Part Number Location:

Lower Manifold Assembly:

Accelerator Cable To Throttle Body:

CAUTIONS:
^ Always remove the fuel pressure regulator to drain excess fuel, and to prevent fuel from entering engine cylinders, when injectors are removed for service. Flooded cylinders could result in engine damage.

^ Use care in removing injectors to prevent damage to the electrical connector pins on the injector, and the nozzle. The fuel injector is serviced as a complete assembly only. Since it is an electrical component, do not soak it in cleaner.

REMOVE OR DISCONNECT
1. Relieve fuel system pressure, refer to Fuel Pressure Release.
2. Negative battery cable.
3. Upper manifold assembly.

WARNING: To reduce the chance of personal injury, cover regulator and fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container after disconnect is completed.

4. Fuel return line retaining bracket nut.
5. Fuel return line retaining bracket and move return line away from regulator.
6. Pressure Regulator Assembly.

CAUTION: To prevent damage to injector retaining bracket and/or injectors, do not try to remove injectors by lifting up the injector retaining bracket while injectors still are installed in bracket slots. Do not attempt to remove bracket without first removing fuel pressure regulator.

7. Injector retainer bracket attaching screws.
8. Injector retainer bracket. Carefully slide bracket off to clear injector slots and regulator.
9. Electrical injector connector(s).

WARNING: To reduce the risk of fire and personal injury, verify that the lower (small) O-ring of each injector does not remain in the lower manifold. If the O-ring is not removed with the injector, the replacement injector, with new O-rings, will not seat properly in the injector socket, and could cause a fuel leak.

10. Fuel injector(s) and discard O-ring seals.

NOTES:
^ Each injector is calibrated for a specific flow rate. When replacing fuel injectors, order replacements with the identical part number as the old injectors.

^ Cover injector sockets to prevent dirt and other contaminants from from entering open fuel passages.

INSTALL OR CONNECT
1. Lubricate new injector O-ring seals with clean engine oil, and install on injector assembly.
2. MFI injector assembly into lower manifold injector socket, with electrical connectors facing inward.
3. Carefully install injector retainer bracket so that injector retaining slots and regulator are aligned with bracket slots.
4. Electrical injector connectors.
5. Pressure Regulator Assembly.
6. Apply Loctite(R) 262 to the injector retainer bracket attaching screws, install and tighten to 3.5 Nm (31 lb in).
7. Upper intake manifold assembly.
8. Accelerator cable bracket with attaching bolts/nuts. Tighten the nut to 30 Nm (22 ft lbs) and the bolts to 25 Nm (18 ft lbs).
9. Tighten fuel filler cap.
10. Negative battery terminal.
11. Turn ignition switch to the "ON" position for two seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position, and check for fuel leaks.
12. Air intake duct.