Fuel Injector: Service and Repair

REMOVAL PROCEDURE

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

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the fuel rail.
4. Remove the fuel injector retaining clip (2).
5. Remove the fuel injector (3).

INSTALLATION PROCEDURE

IMPORTANT: Each fuel injector is calibrated for a specific flow rate. When replacing fuel injectors, be sure to order the correct fuel injector for the application being serviced.

1. Lubricate new fuel injector O-ring seals (1)(4) and (5) with clean engine oil, and install the seals on the fuel injector assembly (3).

IMPORTANT: When installing the fuel injector, care should be taken not to tear or misalign the fuel injector O-rings.

2. Install the fuel injector upper O-ring (1).
3. Install the fuel injector lower back-up O-ring (4).
4. Install the fuel injector lower O-ring (5).
5. Install the fuel injector (3) to the fuel rail.
6. Install the fuel injector retaining clip (2).
7. Install the fuel rail.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

8. Connect the negative battery cable.
9. Inspect for fuel leaks through the following steps:
9.1. Turn ON the ignition, with the engine OFF for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition, with the engine OFF.
9.4. Inspect for fuel leaks.