Fuel Injector: Service and Repair
***UPDATED BY TSB#F00193, JANUARY 11, 19931. Relieve fuel system pressure.
Fuel Pump Electrical Connector And Harness (Under Rear Seat):
a. Remove rear seat cushion and disconnect fuel pump electrical connector.
b. Start engine and let it run until it dies
c. Slowly and carefully remove fuel hose from fuel filter.
Fuel Rails And Injectors:
2. Remove intake air hoses.
3. Disconnect injector electrical connectors.
4. Remove fuel hoses from fuel rails.
5. Use socket and extension to unbolt fuel rails from manifold and remove fuel rails.
6. Remove injector harness/covers from fuel rails.
7. Remove injectors from fuel rails.
8. Install in reverse order.
INSTALLATION NOTES
1. Before installing injectors, be sure injector sockets in the fuel rail are clean and free of burrs or obstructions that might damage O-rings. If cleaning is necessary remove fuel rail, rinse with clean gasoline and blow off with compressed air.
2. When installing injectors, use new O-rings and insulators, and lightly lubricate them with clean engine oil prior to installation (a few drops of two stroke engine oil works well).
Installing Injector In Fuel Rail:
Aligning Injector Tab With Key-Way (Notch) In Fuel Rail:
3. Install injectors by carefully twisting them into their sockets until the tab on the injector fits into the notch in the fuel rail. Then install the rubber spacer and harness/cover. Tighten screws to 30 in.lbs (3.4 Nm).
Fuel Rails With Injectors Installed:
Check For O-Ring Leaks:
4. When all injectors are installed in the fuel rails, connect the fuel hoses, operate fuel pump by jumping between the "FP" and GND" terminals of the diagnostic connector. Check for O-ring leaks at the fuel rail.
Fuel Rail With Insulators Properly Installed:
5. Be sure all insulators and O-rings are properly installed when installing fuel rail. Missing or poorly installed insulators will cause rough idle and possibly driveability problems due to unmeasured air entering the intake system (vacuum leak).
6. Tighten all manifold nuts and bolts to the specified torque.
INJECTOR HARNESS/COVER SCREWS
30 in.lbs (3.4 Nm)
FUEL RAIL BOLTS
14 - 19 ft.lbs (19 - 25 Nm)
Diagnostic/Data Link Connector:
7. When installation is complete, prime fuel rail and injectors by connecting a jumper wire between the "GND" and "FP" terminals of diagnostic connector (see illustration) and turn ignition "ON" for at least ten seconds to operate pump. Then remove jumper wire.