Fuel Injector: Service and Repair

FUEL INJECTOR REPLACEMENT

REMOVAL PROCEDURE




TOOLS REQUIRED
^ J34730, Fuel Pressure Gauge
^ J 43013, Fuel Injector Removal Tool

NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

IMPORTANT: The fuel injector is serviced as a complete assembly only. If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.

1. Relieve the fuel pressure. Refer to the Fuel Pressure Relief Procedure.
2. Remove the fuel injector electrical connector from the fuel injector.




3. Remove the fuel pressure regulator vacuum hose (1) from the fuel pressure regulator (2).




4. Remove the PCV valve hose (1).
5. Remove the throttle body vacuum port hose (2).
6. Remove the wiring harness bolt and harness.

IMPORTANT: It may be necessary to remove the fuel rail from the intake manifold to allow increased fuel rail movement for injector access. Refer to Fuel Rail Assembly Replacement.

7. Release the fuel rail to intake manifold locking tab by pushing away center of intake manifold. Refer to Fuel Rail Assembly Replacement.
8. Remove the fuel injector up out of intake manifold using J 43013 between the bottom of injector and intake manifold.





IMPORTANT: It may be necessary to release the adjacent injector(s) from the intake manifold to allow increased fuel rail movement for injector access.

9. Spread the injector retainer clip (3) to release injector from fuel rail.




10. Remove the fuel injector assembly.
11. Remove the fuel injector upper O-ring (3).
12. Remove the fuel injector lower O-ring (2).
13. Discard the injector O-ring seals.

INSTALLATION PROCEDURE





CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

IMPORTANT: Fuel injector O-rings should always be replaced whenever fuel injectors are serviced.

Each fuel injector is calibrated for a specific flow rate. Be sure to use the correct part number when ordering replacement fuel injectors. Be sure to reinstall the correct O-ring for fuel injector. If the sealing O-ring is not seated properly, a vacuum leak is possible and driveability complaints may occur.

1. Lubricate the new upper (3) and lower (2) O-rings with clean engine oil.
2. Install the new upper and lower injector O-rings on the fuel injector.




3. Install the fuel injector (5) on to fuel rail.
^ Ensure injectors are aligned by orientating electrical connector.
^ Push in the retainer clip (3) far enough to engage retainer clip with machined slots on rail socket.




4. Snap the fuel rail down on to intake manifold.
5. Install the fuel injector electrical connector to the fuel injector.
6. Install the wiring harness holddown bolt.




7. Install the throttle body vacuum port hose (2).
8. Install the PCV valve hose (1).




9. Install the fuel pressure regulator vacuum hose (1) to the fuel pressure regulator (2).
10. Install the negative battery cable.
10.1. Turn ignition switch to ON position for 2 seconds.
10.2. Turn the ignition switch OFF for 10 seconds.
10.3. Turn the ignition switch ON.
10.4. Check for fuel leaks.




11. Install the fuel injection sight shield.