Fuel Injector: Service and Repair

FUEL RAIL AND INJECTORS

(Numbers seen within images reflect procedure step numbers)

Remove

1. Disconnect battery negative lead.
2. Depressurize fuel system. See: FUEL DELIVERY AND AIR INDUCTION / FUEL PRESSURE RELEASE / SERVICE AND REPAIR.
3. Release plenum chamber and place aside. See: FUEL DELIVERY AND AIR INDUCTION / INTAKE AIR PLENUM / SERVICE AND REPAIR.





4. Release purge hose, crankcase breather hose and pressure regulator vacuum hose from ram housing.
5. Remove 6 bolts securing ram housing to inlet manifold.
6. Place small packing block on inlet manifold. Lever between packing block and ram pipe housing to break seal.

CAUTION: Do not lever or pry against fuel rail.

7. Remove ram housing from 2 dowels.
8. Place cloth over inlet manifold to prevent debris from entering.





9. Disconnect 8 injector multiplugs.
10. Disconnect fuel temperature sensor multiplug.
11. Disconnect fuel feed hose from fuel rail.
12. Disconnect fuel return hose from pressure regulator pipe.
13. Remove 6 nuts securing fuel rail and ignition coil bracket to inlet manifold.
14. Release ignition coil bracket from inlet manifold studs. Place aside.
15. Release injectors from inlet manifold and remove fuel rail assembly. Do not carry out further dismantling if component is removed for access only.
16. Remove 8 clips securing injectors to fuel rail. Remove injectors.
17. Remove 2 O-rings from each injector and discard.





18. Remove 2 screws securing fuel pressure regulator to fuel rail.
19. Release return pipe from clip. Remove pressure regulator assembly.
20. Remove O-ring from fuel pressure regulator and discard.

Refit

21. Ensure mating surfaces between inlet manifold and ram pipe housing are clean.
22. Ensure all locations in fuel rail and inlet manifold are clean.
23. Fit new O-rings to injectors and fuel pressure regulator.
24. Lubricate O-rings with silicone grease.
25. Fit fuel pressure regulator to fuel rail. Secure with bolts.

Tighten to 10 Nm (7 ft.lb.)

26. Engage regulator return pipe in clip.
27. Fit injectors to fuel rail. Secure with clips.
28. Position fuel rail to inlet manifold. Engage injectors, one bank at a time.
29. Position ignition coil bracket on inlet manifold studs.
30. Secure ignition coil bracket and fuel rail to inlet manifold with nuts.

Tighten to 8 Nm (6 ft.lb.)

31. Connect return hose to pressure regulator pipe. Secure with clip.
32. Connect fuel feed pipe to fuel rail.

Tighten union to 16 Nm (12 ft.lb.)

33. Connect multi plugs to fuel injectors and fuel temperature sensor.
34. Remove cloth from inlet manifold.
35. Apply a thin, uniform coating of Loctite 577 or equivalent sealant to mating face of inlet manifold.
36. Fit ram pipe housing to inlet manifold. Secure with bolts.

Tighten to 24 Nm (18 ft.lb.)

37. Connect purge hose, crankcase breather hose and pressure regulator vacuum hose to ram pipe housing.
38. Fit plenum chamber. See: FUEL DELIVERY AND AIR INDUCTION / INTAKE AIR PLENUM / SERVICE AND REPAIR.
39. Reconnect battery negative lead.
40. START engine. Check for leaks around fuel rail and injectors.