Fuel Injector: Service and Repair

REMOVAL

1. Release pressure from fuel system. A relief valve on the fuel rail is provided for this.

Fuel Injection Supply Manifold:

2. Disconnect fuel hoses at the fuel rail supply and return tubes.

Fuel Injection Supply Manifold And Related Components:

3. Carefully remove electrical harness connectors from individual injectors.

4. Remove fuel supply manifold mounting bolts. Remove the fuel supply manifold from the engine.

Fuel Injector:

5. Grasp fuel injector body, pull up while gently rocking injector from side to side.

6. Inspect injector "plastic hat" (covering the injector pintle) and washer for signs of deterioration. Replace as required. If hat is missing look for it in intake manifold.

INSTALLATION

1. Replace and lubricate the two injector O-rings on each injector with clean engine oil.

NOTE: Never use silicone lubricant. It will clog the injectors.

2. Install injectors. Use a light, twisting, pushing motion to install them.

3. Install fuel injection supply manifold and secure using four retaining bolts. Tighten to 8.0-12.0 Nm (71-106 lb in).

4. Connect fuel inlet and outlet lines at fuel rail connections. Push in to connect.

5. Install fuel line to fuel injection supply manifold retaining clips.

6. Install electrical harness connector to fuel injectors.

7. Install upper intake manifold.

8. Turn key ON/OFF several times without starting engine to check for fuel leaks.

NOTE: Check all connections at fuel rails, push connect fittings, etc.

9. Start engine and warm to operating temperature. Check for coolant leak if coolant was removed.