Fuel Injector: Service and Repair

REMOVAL PROCEDURE




1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

2. Disconnect the negative battery cable.
3. Remove the PCV valve and hose (2) from the intake and the valve cover.
4. Remove the three bolts (3) and the intake manifold brace (1) from the engine.
5. Disconnect the four fuel injector electrical connectors.
6. Disconnect the fuel pressure regulator vacuum hose.




7. Remove the fuel feed hose (2) from the fuel rail inlet pipe.
8. Remove the fuel return hose (1) from the fuel rail return pipe.




9. Remove the two bolts (2) from the fuel rail (3).
10. Remove the fuel rail from the intake manifold.
11. Remove the four fuel injectors from the fuel rail.

INSTALLATION PROCEDURE

IMPORTANT: Always replace the fuel injector O-rings with new O-rings when servicing the fuel injectors. Do not damage the O-rings during installation.




1. Install a new O-ring (1) with a grommet (2) onto each fuel injector (3).
2. Apply a thin coat of fuel to the fuel injector O-rings and install the injectors to the fuel rail.

IMPORTANT: Inspect the fuel injector cushions for scoring or damage. Replace any faulty fuel injector cushions before installation to the intake manifold.

3. Install the fuel rail and the four fuel injectors, with cushions (4), onto the intake manifold.

NOTE: Refer to Fastener Notice in Cautions and Notices.




4. Attach the fuel rail (3) and insulators (1) to the intake manifold with the two bolts (2).

Tighten
Tighten the two fuel rail bolts to 18-28 N.m (13-20 lb ft).


IMPORTANT: An incorrectly installed fuel injector O-ring can prevent the fuel injector from rotating freely. Inspect for binding fuel injector O-rings and replace as necessary.




5. Check that the fuel injectors rotate smoothly and freely.




6. Install the fuel feed hose (2) to the fuel rail inlet pipe and secure with the clamp.
7. Install the fuel return hose (1) to the fuel rail return pipe and secure with the clamp.
8. Connect the fuel pressure regulator vacuum hose to the fuel pressure regulator.
9. Connect the four fuel injector electrical connectors to the fuel injectors.




10. Install the intake manifold brace (1) to the engine and secure with the three bolts (3).

Tighten
Tighten the three bracket bolts to 25-35 N.m (18.5-25 lb ft).

11. Install the PCV valve and hose (2) to the intake plenum and valve cover.
12. Connect the negative battery cable.

Tighten
Tighten the negative battery cable-to-negative battery terminal retainer to 5.5 N.m (49 lb in).

13. Turn ON the ignition, in order to pressurize the fuel system.
14. Turn OFF the ignition.
15. Check for any fuel leaks and repair as necessary.