Fuel Injector: Service and Repair
Removal ProcedureDescription:
1. Remove the throttle body. Refer to Throttle Body Replacement.
Description:
2. Remove the Exhaust Gas Recirculation (EGR) pressure transducer from the pressure transducer bracket.
3. Remove the two bolts (3) from the EGR pressure transducer(1) bracket (2) to the intake manifold.
4. Remove the EGR pressure transducer bracket (2) from the intake manifold.
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5. Disconnect the four fuel injector electrical connectors (1).
Description:
6. Remove the two bolts (2) from the fuel pressure regulator (1) to the fuel rail.
Description:
7. Remove the fuel pressure regulator (1) from the fuel rail.
8. Remove the fuel pulsation damper from the fuel rail.
9. The fuel feed pipe from the fuel rail.
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10. Remove the three bolts (7) from the fuel rail to the intake manifold.
11. Remove the fuel rail from the intake manifold.
12. Remove the four fuel injectors from the intake manifold.
Installation Procedure
Important: Always replace fuel injector O-rings with new O-rings when servicing the fuel injectors, taking care not damage them during installation.
Description:
1. Install the new O-rings (3) on the fuel injectors (6).
2. Install the grommets (2) to the fuel injectors (6).
Inspect:
Inspect the insulators for breakage or scoring. If damaged, replace the insulator(s).
Description:
3. Install the three insulators (2) to the intake manifold.
4. Install the four cushions (1) to the intake manifold.
5. Apply a thin coat of fuel to the fuel injector O-rings and install the injectors to the fuel rail.
6. Install the fuel rail with injectors to the intake manifold.
Important: Make sure that the fuel injectors rotate smoothly. If not, check for an incorrectly installed O-ring and replace with a new O-ring.
Description:
7. Install the three bolts (3) to the fuel rail. Tighten the three fuel rail bolts to 18-28 Nm (13-20 lb. ft.).
Important: After securing the fuel rail make sure that the fuel injectors rotate smoothly.
8. Install the fuel feed pipe to the fuel rail.
9. Install the fuel pulsation damper and gasket to the fuel rail.
Important: Apply a thin coat of engine oil to new gaskets. Tighten the fuel pulsation damper to 25-35 Nm (18.5-25 lb. ft.).
10. Install the fuel pressure regulator to the fuel rail.
Description:
11. Secure the fuel pressure regulator to the fuel rail with two bolts (2). Tighten the fuel pressure regulator bolts to 8-12 Nm (6-8.5 lb. ft.).
12. Connect the four fuel injector electrical connectors (1).
13. Install the EGR pressure transducer bracket to intake manifold.
14. Secure the EGR pressure transducer bracket with two bolts. Tighten the EGR pressure transducer bracket bolts to 23 Nm (17 lb. ft.).
15. Install the EGR pressure transducer to the EGR pressure transducer bracket.
16. Install the throttle body. Refer to Throttle Body Replacement.