Fuel Injector: Service and Repair

REMOVAL

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. Drain the engine coolant to below the level of the intake manifold dynamic chamber.

Fuel Injectors And Intake System Components:

3. Remove the intercooler.

4. Disconnect all electrical connectors, cables, and hose connections from the throttle body and dynamic chamber and attached components.

NOTE: It is not necessary to remove hoses that only connect between the throttle body and dynamic chamber, since these will be removed as an assembly.

5. Remove the oil filler pipe.

6. Remove the attaching nuts and bolts holding the dynamic chamber to the lower section of the intake manifold. It may be necessary to remove the AWS solenoid valve and BAC valve to gain easy access to the manifold fasteners.

7. Remove the dynamic chamber with the throttle body attached, as an assembly.

8. Remove the fuel rails.

9. Remove the fuel injectors.

10. Remove the air bleed sockets and mixing plates from the manifold.

INSTALLATION NOTES

Installing Primary Injector Mixing Plates:

1. When installing the air bleed sockets and mixing plates, be sure they are fully seated and key tab is fitted into locating notch, as shown in illustration.

Secondary Fuel Rail (Delivery Pipe) And Injector:

2. Always use new insulators and O-rings, and lubricate them with a few drops of clean engine oil prior to installation.

Aligning Primary Injectors By Connector Position:

Aligning Secondary Injectors By Connector Position:

3. When installing injectors, be sure injectors are properly inserted at both ends so as not to damage insulators and O-rings. Align injectors by their connector positions, as shown in illustrations, before tightening down the fuel rails.

4. Install remaining components in the reverse order of removal, tighten dynamic chamber to manifold nuts and bolts to the specified torque.

14 - 19 ft.lbs (19 - 25 Nm)