Fuel Injector: Service and Repair

Removal Procedure

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Remove the upper intake manifold assembly. Refer to Intake Manifold Replacement (Upper) in Engine Mechanical - 4.3L.
4. Remove the fuel meter body assembly. Refer to Fuel Meter Body Assembly Replacement.
5. Remove the injector assembly retainer (11) and the injector retainer lock nuts (10).

NOTE: Use care in removing the fuel injectors to prevent damage to the electrical connector terminals, the injector filter, and the fuel nozzle.

6. The fuel injector is serviced as a complete assembly only.

Also since the injectors are electrical components, these injectors should not be immersed in any type of liquid solvent or cleaner as damage may occur.

While pulling the poppet nozzle tube downward, push with a small tip punch down between the injector terminals until the injector is removed.




Installation Procedure

Important: Each injector is calibrated for a specific flow rate. Order the correct injector for the application being serviced when replacing the fuel injectors.

1. Lubricate the new injector O-ring seals with clean engine oil (2).




2. Install the O-rings on the injector assembly (2).
3. Install the fuel injector assembly (12) into the fuel meter body injector socket.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the injector assembly retainer (11) and the injector retainer lock nuts (10).

Tighten:
Tighten the injector retainer lock nuts to 3.0 N.m (27 lb in).

5. Install the fuel meter body assembly. Refer to Fuel Meter Body Assembly Replacement.
6. Install the upper intake manifold assembly. Refer to Intake Manifold Replacement (Upper) in Engine Mechanical - 4.3L.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Inspect for leaks.
1. Turn the ignition switch ON for 2 seconds.
2. Turn the ignition switch OFF for 10 seconds.
3. Turn the ignition switch ON.
4. Inspect for fuel leaks.