Fuel Injector: Service and Repair

REMOVAL PROCEDURE




1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the PCV valve and the hose (2) from the intake and from the valve cover.
4. Remove the 3 bolts (3) and the intake manifold brace (1) from the engine.
5. Disconnect the electrical connectors from the 4 fuel injectors.
6. Disconnect the vacuum hose from the fuel-pressure regulator.




7. Remove the fuel feed hose (2) from the fuel rail inlet pipe.
8. Remove the fuel return hose (1) from the fuel rail return pipe.




9. Remove the 2 bolts (2) from the fuel rail (3).
10. Remove the fuel rail from the intake manifold.
11. Remove the 4 fuel injectors from the fuel rail.

INSTALLATION PROCEDURE

IMPORTANT: Always replace the fuel injector O-rings with new O-rings when servicing the fuel injectors. Do not damage the O-rings during the installation.




1. Install a new O-ring (1) and a grommet (2) onto each fuel injector (3).
2. Apply a thin coat of fuel to the fuel injector O-rings, and install the injectors to the fuel rail.

IMPORTANT: Inspect the fuel injector cushions for scoring or for damage. Before installing the fuel injectors to the intake manifold, replace any faulty injector cushions.

3. Install the fuel rail and the 4 fuel injectors, with the cushions (4), onto the intake manifold.

NOTE: Refer to Fastener Notice in Service Precautions.




4. Use the 2 bolts in order to install the fuel rail (3) and the insulators (1) to the intake manifold.

Tighten
Tighten the bolts to 18-28 N.m (13-20 lb ft).

IMPORTANT: An incorrectly installed fuel injector O-ring can prevent the fuel injector from rotating freely. Inspect for binding fuel injector O-rings, and replace any O-rings as necessary.




5. Verify that the fuel injectors rotate smoothly and freely.




6. Install the fuel feed hose (2) to the fuel rail inlet pipe, and secure the hose with the clamp.
7. Install the fuel return hose (1) to the fuel rail return pipe, and secure the hose with the clamp.
8. Connect the vacuum hose to the fuel-pressure regulator.
9. Connect the electrical connectors to the fuel injectors.




10. Install the intake manifold brace (1) to the engine with the 3 bolts (3).

Tighten
Tighten the bolts to 25-35 N.m (18.5-25 lb ft).

11. Install the PCV valve and the hose (2) to the intake plenum and to the valve cover.
12. Connect the negative battery cable.

Tighten
Tighten the negative battery terminal retainer to 5.5 N.m (49 lb in).

13. Turn ON the ignition in order to pressurize the fuel system.
14. Turn OFF the ignition.
15. Check for any fuel leaks, and repair any leaks as necessary.