Fuel Injector: Service and Repair

REMOVAL PROCEDURE

CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.

After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the fuel rail assembly.
4. Remove the fuel injector retaining clip (1).

IMPORTANT:
^ If the fuel injector is difficult to remove from the fuel rail assembly, use the J43013 Multec II Injector Removal Tool.
^ Visually inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring is not removed, remove the O-ring from the fuel rail assembly.

5. Remove the fuel injector.

INSTALLATION PROCEDURE

IMPORTANT: Each fuel injector is calibrated for a specific flow rate. When replacing the fuel injectors, be sure to order the correct fuel injector for the application.

1. Lubricate the new fuel injector O-ring seals (2,3) with clean engine oil, and install the seals on the fuel rail assembly.

IMPORTANT: When installing the fuel injector, care should be taken not to tear or misalign the fuel injector O-rings.

2. Install the fuel injector upper O-ring (3).
3. Install the fuel injector lower O-ring (2).
4. Install the fuel injector to the fuel rail assembly.
5. Install the fuel injector retaining clip (1).
6. Install the fuel rail assembly.
7. Reconnect the negative battery cable.
8. Use the following procedure in order to inspect for fuel leaks:
8.1. Turn on the ignition for 2 seconds, leaving the engine off.
8.2. Turn off the ignition for 10 seconds.
8.3. Turn on the ignition, leaving the engine off.
8.4. Inspect for fuel leaks.