Fuel Injector: Service and Repair

Fuel Rail and Injectors Removal and Installation

Removal

WARNING: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

1. Relieve the fuel system pressure. Refer to Fuel System Pressure Release.
2. Disconnect the negative battery cable.
3. Disconnect the intake air temperature (IAT) sensor connector.




4. Disconnect the breather hose from the valve cover.
5. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
6. Disconnect the throttle cables from the throttle body and the bracket.
7. Disconnect the fuel feed line at the fuel rail.




8. Remove the fuel rail retaining bolts.




9. Remove the fuel rail with the injectors attached.
10. Remove the fuel injector retainer clips.
11. Remove the fuel injectors by pulling them down and out.




12. Discard the fuel injector O-rings.

Installation

CAUTION: Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
3. Install the fuel injector retaining clips onto the fuel injector and the fuel rail ledge.




4. Make sure that the clips are parallel to the fuel injector harness connector.
5. Install the fuel rail assembly into the cylinder head.
6. Install the fuel rail retaining bolts. Tighten:

Tighten the fuel rail retaining bolts to 25 Nm (18 ft. lbs.).

7. Connect the fuel feed line to the fuel rail.




8. Connect the fuel injector connectors. Rotate each fuel injector as required.
9. Connect the PCV hose to the valve cover.
10. Connect the breather hose to the valve cover.
11. Connect the IAT sensor connector.
12. Connect the negative battery cable.




13. Perform a leak check of the fuel rail and fuel injectors.