Fuel Injector: Service and Repair

Removal Procedure

Caution: Use care in removing the fuel injectors to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. The fuel injector is an electrical component and should not be immersed in any type of cleaner as damage to the fuel injector may result.

Caution: 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 fuel system pressure. Refer to Fuel Pressure Release
2. Remove the upper intake manifold. Refer to Upper Intake Manifold.
3. Remove the fuel rail. Refer to Fuel Rail Assembly
4. Remove the fuel injector retaining clips.
5. Remove the fuel injectors.

Installation Procedure

Important: Each fuel injector is calibrated for a specific flow rate. Be sure to use the correct pant number when ordering replacement fuel injectors. When replacing the fuel injector O-rings, be sure to install the brown O-ring in the lower position. The fuel injector lower O-ring uses a nylon collar, called the O-ring backup, to properly position the O-ring on the fuel injector. Be sure to reinstall the O-ring backup, or the sealing O-ring may move on the fuel injector when installing the fuel rail. If the sealing O-ring is not seated properly, a vacuum leak is possible and driveability complaints may occur.

1. Install the fuel injectors using new O-rings. Coat the O-rings with clean engine oil. The brown O-ring is to be used in the lower position only.
2. Install the fuel injector retaining clips.
3. Install the fuel rail. The fuel injectors are retained by the fuel rail. Refer to Fuel Rail Assembly
4. Install the upper intake manifold. Refer to Upper Intake Manifold.
5. Install the fuel filler cap.