Fuel Injector: Service and Repair

Fuel Pump Fuse:

REMOVAL
1. Remove the fuse for the fuel pump (located in the fuse panel in the left kick panel).
2. Turn the ignition key to the start position for approximately 15 seconds (this will release the fuel pressure).
3. Disconnect the following from the intake plenum:
^Plenum cover.
^Air duct.
^Accelerator cable.
^Rocker hoses.
^Coolant by-pass hoses (2).
^Harness clamps.
^Harness connectors.
^Fuel hoses.
^EGR tube.

Plenum Bolts:

4. Remove the plenum bolts and remove plenum.

Fuel Rail Bolts:

5. Remove the fuel rail securing bolts in order shown.
6. Remove the injector securing bolts.
NOTE: Make a note or sketch of the position of injector terminals in relation to where the wiring harness was situated. This will aid in reassembly.
7. Remove injectors and rail as an assembly.
WARNING: Do not place the injector or fuel rail in a vise, this may cause irreparable damage.
8. Using a sharp knife or a single edge razor blade cut through the hose (do not damage the fuel rail when cutting).
9. Remove the injector and hose.

INSTALLATION
1. Clean all parts (including the sealing area on the manifold) with a suitable cleaner.
2. Install new o-rings and seals (check the insulators for damage and replace if necessary. Also check the electrical connectors for corrosion and cracked insulators or boots).
3. Lubricate the seals and hoses with unleaded fuel only.
4. Reinstall in reverse order with a new plenum gasket and check for fuel leaks.