Fuel Injector: Service and Repair

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY.

CAUTION: After disconnecting, plug the fuel lines to prevent leakage.

1. Disconnect the battery ground cable.
2. Remove the intake manifold-spacer assembly.







3. Remove the fuel pressure regulator valve vacuum hose.
4. Disconnect the fuel lines.







5. Disconnect the six fuel injector electrical connectors.

NOTE: One fuel injector is shown, all are similar.







6. Disconnect the fuel injector electrical harness from the fuel injector manifold.







7. Remove the fuel injection supply manifold.
1 Remove the four bolts.
2 Remove the fuel injection supply manifold.

NOTE: Left side shown, right side similar.







8. Remove the six fuel injector retaining clips and the fuel injectors. Inspect and install new fuel injector O-rings if necessary.

CAUTION: The fuel injectors are deposit-resistant. Do not clean. Use O-rings made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak.

INSTALLATION







1. To install, reverse the removal procedure.

CAUTION: The injector clips must engage the upper groove on the injectors or fuel leaks can occur.

NOTE: Lubricate the new O-rings with clean engine oil to aid installation.