Removal

Removal Procedure

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

^ Use care in removing the fuel injectors in order 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.

Notice: In order to prevent possible engine damage from flooded cylinders, the following procedures must be performed.


1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair

2. Disconnect the negative battery cable.

3. Remove the upper manifold assembly.


Caution:
^ In order to reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components.

^ After relieving system pressure, a small amount of fuel may be released when servicing fuel pipes or connections. In order to reduce the chance of personal injury, cover fuel pipe fittings with a shop towel before disconnecting the fuel pipes in order to catch any fuel that may leak out. Place the towel in an approved container when the disconnect is completed.

4. Fuel return pipe retaining bracket nut (8).

5. Fuel return pipe retaining bracket, move return pipe away from regulator.


Notice:
^ In order to prevent damage to the fuel injector retaining bracket and fuel injectors, do not try to remove the fuel injectors by lifting up the fuel injector retaining bracket while the fuel injectors are still installed in the bracket slots.

^ Do not attempt to remove the bracket without first removing the fuel pressure regulator.

6. Remove the pressure regulator assembly (6).

7. Remove the injector retainer bracket attaching screws (11).

8. Remove the injector retainer bracket (12). Carefully slide bracket off to clear fuel injector slots and regulator.

Caution: In order 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.

9. Remove the injector electrical connector(s).

10. Remove the fuel injector(s) (5). Discard O-ring seals (4).