Fuel Injector: Service and Repair

WARNING:
To reduce the risk of fire and personal injury, verify that the lower (small) O-ring of each injector does not remain in the lower manifold. If the O-ring is not removed with the injector, the replacement injector, with new O-rings, will not seat properly in the injector socket and could cause a fuel leak.

CAUTION:
Always remove the fuel pressure regulator to drain excess fuel, and to prevent fuel from entering engine cylinders when injectors are removed for service. Flooded cylinders could result in engine damage.

Use care in removing injectors to prevent damage to the electrical connector pins on the injector and the nozzle. The fuel injector is serviced as a complete assembly only. Since it is an electrical component, do not soak it in cleaner.

REMOVE OR DISCONNECT
1. Relieve fuel system pressure.
^ Refer to Fuel System / Service and Repair [1][2]Fuel System Pressure Relief Procedure
2. Negative battery cable.
3. Upper manifold assembly.
4. Fuel return pipe retaining bracket nut.
5. Fuel return pipe retaining bracket.
^ Move return pipe away from regulator.
6. Pressure regulator assembly.

CAUTION:
^ To prevent damage to injector retaining bracket and/or injectors, do not try to remove injectors by lifting up the injector retaining bracket while injectors still are installed in bracket slots.
^ Do Not attempt to remove bracket without first removing fuel pressure regulator.

7. Injector retainer bracket attaching screws.
8. Injector retainer bracket.
^ Carefully slide bracket off to clear injector slots and regulator.
9. Injector electrical connector(s).
10. Fuel injector(s).
^ Discard O-ring seals.


NOTICE:
- Each injector is calibrated for a specific flow rate. When replacing fuel injectors, be sure to order the correct injector for the application being serviced. Refer to Application and ID.
- Cover injector sockets to prevent dirt and other contaminants from entering into open fuel passages.

INSTALL OR CONNECT
1. Lubricate new injector O-ring seals with clean engine oil, and install on injector assembly.
2. Bottom feed multiport injector assembly into lower manifold injector socket with electrical connectors facing inward.
3. Injector retainer bracket.
^ Carefully install bracket so that injector retaining slots and regulator are aligned with bracket slots.
4. Injector electrical connectors.
5. Pressure regulator assembly.
6. Injector retainer bracket attaching screws.

Tighten
Retainer bracket attaching screws to 3.5 Nm (31 lb. in.)

7. Upper manifold assembly.
8. Fuel return pipe retaining bracket.
9. Accelerator cable bracket with attaching bolts/nuts.

Tighten
Bracket nut to 30 Nm (22 lb. ft.).
Accelerator cable bracket bolts to 25 Nm (18 lb. ft.).

10. Tighten fuel filler cap.
11. Negative battery cable.


Inspect
Turn ignition switch to the "ON" position for two seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position and check for fuel leaks.

12. Air intake duct.