Fuel Injector: Service and Repair

Fuel Injector Removal:

NOTES:

a. Each fuel injector is serviced as a complete assembly only.

b. Use care in removing the fuel injectors to prevent damage to the electrical connector terminals, the injector filter, and the fuel nozzle. The fuel injector is serviced as a complete assembly only. Also, since the injectors are electrical components, they should not be immersed in any type of liquid solvent or cleaner as damage could occur.

REMOVAL:

1. Disconnect electrical connectors to fuel injectors. (Squeeze plastic tabs and pull straight up.)
2. Remove fuel meter cover assembly, refer to FUEL METER COVER ASSEMBLY.
3. With fuel meter cover gasket in place to prevent damage to casting, use a screwdriver and fulcrum to carefully lift out each injector.
4. Remove lower (small) O-rings from nozzle of injectors and discard.
5. Remove fuel meter cover gasket and discard.
6. Remove upper (large) O-rings and steel backup washers from top of fuel injector cavity and discard.

INSPECTION:

Inspect the fuel injector filter for evidence of dirt and contamination. If present, check for presence of dirt in fuel lines and fuel tank. If dirt is present refer to MAINTENANCE PROCEDURES/FUEL SYSTEM CLEANING.

Fuel Injector Color Code Locations:

Fuel Injector Part Number Location:

NOTE:

a. The TBI unit has two different fuel injectors (with two different flow rates). Injectors having part number 5235134 (color coded Orange and Green) should be installed on the throttle lever side. Those with part number 5235342 (color coded Pink and Brown) go on the TPS side.

b. Be sure to replace the injector with an identical part. Different injectors with different flow rates will fit this unit, but are calibrated for different flow rates.

Fuel Injector Installation:

INSTALLATION:

1. Lubricate new lower (small) O-rings with automatic transmission fluid and push on nozzle end of injector until it presses against injector fuel filter.
2. Install steel injector back up washer in counterbore of fuel meter body.
3. Lubricate new upper (large) O-rings with automatic transmission fluid and install directly over the back up washer. Be sure the O-ring is seated properly and is flush with top of fuel meter body surface.
NOTE: Backup washers and O-rings must be installed before injectors, or improper seating of large O-rings could cause fuel to leak.
4. Install injector, aligning raised lug on each injector base with notch in fuel meter body cavity. Push down on injector until it is fully seated in the fuel meter body. (Electrical terminals of the injector should be parallel with throttle shaft).
5. Install fuel meter cover gasket.
6. Install fuel meter cover.
7. Reconnect electrical connectors to fuel injectors.
8. With engine OFF and ignition ON, check for fuel leaks.