Fuel Injector: Service and Repair

FUEL INJECTORS

Part 1:

Part 2:

Exploded View

Disconnect Tool, Spring Lock Coupling:

Special Tools(s)

Removal and Installation

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 may 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.

1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the air cleaner inlet pipe.
4. Disconnect the mass air flow (MAF) sensor electrical connector.
5. Disconnect the brake booster vacuum hose.
6. Disconnect the positive crankcase ventilation (PCV) tube.
7. Disconnect the crankcase ventilation tube.
8. Disconnect the fuel supply tube spring lock coupling.
9. Disconnect the 8 fuel injector electrical connectors.
10. Remove the 8 fuel injector-to-fuel rail locking clips
11. Remove the 4 fuel rail bolts and the fuel rail.
- To install, tighten to 10 Nm (89 lb-in).







12. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. Lubricate the O-ring seals with clean engine oil prior to installation.

Remove the fuel injectors and the fuel injector O-ring seals.
- Discard the O-ring seals.

13. To install, reverse the removal procedure.