Fuel Injector: Service and Repair

REMOVAL

1. Remove the upper intake manifold.

2. Disconnect fuel line retaining clips.

Fuel Injector:

3. Carefully remove electrical harness connectors from individual fuel injectors.

4. Relieve fuel system pressure before disconnecting coupling.

5. Disconnect fuel hoses at the fuel rail supply tube and fuel rail return tube.

a. Fit tool to coupling so tool can enter cage to release garter spring.

b. Push the tool into the cage opening to release female fitting from garter spring.

c. Pull the coupling male and female fittings apart.

d. Remove the tool from the disconnected coupling.

6. Disconnect the vacuum line to the fuel pressure regulator.

7. Remove the strap surrounding the fuel injection supply manifold, injector electrical harness, and the main vacuum harness.

8. Remove the three fuel injection supply manifold retaining studs.

9. Remove fuel injection supply manifold.

10. Grasp injector body and pull up while gently rocking fuel injector from side to side, to remove fuel injector.

INSTALLATION

Fuel Injector:

1. Make sure injector caps are clean and free of contamination.

Fuel Injectors And Related Components:

2. Install the fuel injectors into the fuel injection supply manifold first to avoid damage to the O-rings.

3. Secure the fuel injection supply manifold using the three retaining bolts. Tighten to 8.0-12 Nm (70-1O5 lb in).

4. Attach the vacuum line to the fuel pressure regulator.

5. Secure the main vacuum harness and the injector electrical harness to the fuel injection supply manifold with a strap positioned between the No. 5 and No. 6 intake manifold runners.

6. Connect the fuel inlet and outlet lines at the fuel injection supply manifold connections.

a. Check for missing or damaged garter spring. Remove damaged spring with small hooked wire.

b. Install new spring if damaged or missing.

c. Clean fittings.

d. Install new O-rings.

e. Lubricate with clean engine oil.

f. Assemble fitting by pushing with a slight twisting motion.

g. To ensure coupling engagement visually check to be sure garter spring is over flared end of female fitting.

8. Connect fuel line retaining clips.

9. Install the upper intake manifold.