Fuel Injector: Service and Repair

NOTE: Perform Fuel System Pressure Release before proceeding.

The injectors and the fuel rail are removed together as an assembly.

FUEL RAIL REMOVAL

Fuel Rail And Components:

1. Remove the air intake surge tank.
2. Disconnect the battery negative terminal.
3. Disconnect the high pressure fuel line from the fuel rail.

CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the fuel rail or line.

4. Disconnect and remove the fuel rail crossover pipe.
5. Disconnect the fuel return line from the fuel regulator.
6. Remove the fuel rail mounting bolts.
7. Remove the fuel rails, separately with the injectors and regulator in position. Being careful not to drop any of the injectors while removing the rail.
8. Remove the injectors from the fuel rail.

NOTE: Fuel may spill out of the fuel rail when the injectors are removed.

FUEL RAIL INSTALLATION

Fuel Injector Insulators:

1. Install new insulators to the intake manifold.

Injector Seals:

2. Install new grommets and O-rings to the injectors.
3. Apply unleaded gasoline to the O-ring of the injector.

Injector Installation:

4. While turning the injector to the left and right, install it on to the fuel rail.
5. Be sure the injector turns smoothly.

NOTE: If it does not turn smoothly, the O-ring may be jammed, remove the injector and re-insert it into the fuel rail. Re-check that the injector turns smoothly.

Fuel Rail Insulator:

6. When installing the fuel rail, check to be sure that the rail insulator is correctly inserted into the installation holes. Tighten the mounting bolts.

Torque value: 10 - 13 Nm (7 - 9 ft.lbs.)

O-ring Lubrication Points:

7. When connecting the high pressure fuel hose and the crossover pipe to the fuel rail, apply fuel to the hose union, and then insert, being careful not to damage the O-ring.

High pressure hose torque: 5 Nm (4 ft.lbs.)

Torque value: 10 - 13 Nm (7 - 9 ft.lbs.)

8. Install the fuel pressure regulator to the fuel rail, if removed.

Torque value: 9 Nm (7 ft.lbs.)

9. After replacement of the fuel rail and injectors, check for leaks with the system pressurized.