Fuel Injector: Service and Repair

REMOVAL

Fuel And Intake System Components:

1. Relieve fuel system pressure by starting engine with fuel pump relay (circuit open relay) disconnected and let run until engine dies. Then slowly and carefully remove hose on outlet side of fuel filter. Cover with a clean rag while removing hose, to avoid spraying fuel in your face. On the 929 DOHC V-6 engine, fuel system pressure can also be relieved by gradually and carefully loosening the banjo bolt on the cold start valve (on top of the throttle body). Cover with a clean rag when doing so, to avoid spraying fuel.



2. Drain engine coolant to below the level of the intake manifold.

3. Remove intake air duct and air funnel from throttle body.

4. Remove dynamic chamber cover.

5. Disconnect vacuum hoses, cables, electrical connectors, and water hoses from throttle body, BAC valve, and dynamic chamber.

6. Remove cold start valve fuel hose from valve.

7. Remove dynamic chamber from intake manifold.

8. Disconnect fuel inlet and return hoses from fuel rail.

9. Disconnect fuel injector electrical connectors and remove fuel rail and injectors.

NOTE: Keep all open fuel system connections covered or plugged to keep out dirt and other contamination during servicing. Keep all fuel system components clean and store in a clean place (don't store injectors in the same box with other parts, nuts, and bolts, etc.)

Install in reverse order.

INSTALLATION NOTES

Fuel Injector:

1. When installing injectors, use new O-rings and insulators, and lightly lubricate them with clean engine oil prior to installation.


2. Tighten all manifold nuts and bolts to the specified torque.

MANIFOLD BOLTS AND NUTS
14 - 19 ft.lbs (19 - 25 Nm)

FUEL RAIL AND LIGHT DUTY BRACKET BOLTS
6 - 8 ft.lbs (8 - 11 Nm)