Fuel Injector: Service and Repair

REMOVAL

Underhood View Of Intake System:

Fuel And Intake System Assembly:

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.

2. Disconnect air funnel/hose from throttle body.

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

4. Disconnect vacuum hoses, cables, and water hoses from throttle body and BAC valve.

Intake Air Pipe Installation:

5. Remove throttle body and intake air pipe as an assembly.

6. Remove VRIS valve and solenoid valve cover and disconnect vacuum hose from VRIS solenoid.

7. Unbolt extension manifolds from dynamic chamber, and remove them and the dynamic chamber from the intake manifold.

Right And Left Bank Extension Manifolds:

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NOTE: There are three right side and three left side extension manifolds. Note and mark their positions during dis-assembly to make reassembly easy.

8. Disconnect the fuel inlet and return hoses from the fuel rails.

9. Disconnect fuel injector electrcal connectors, then remove the fuel rails 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).

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.

Dynamic Chamber And Intake Manifold (Installation):

Extension Manifold, Gasket, And O-Ring:

2. When installing dynamic chamber and extension manifolds, use a new drain hole O-ring under the dynamic chamber, and new O-rings and gaskets on the extension manifolds. Lightly lubricate O-rings with clean engine oil prior to installation. Use an appropriate sealer or adhesive to hold gaskets in place during assembly, if necessary.

3. 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)