Fuel Injector: Service and Repair
Fuel Injector Replacement
Special Tools
* EN-47909 - Injector Bore and Sleeve Cleaning Kit
* EN-48266 - Injector Seal Installer and Sizer
* J-37281-A - Injector Remover
* J 39313 - Spark Plug Port Adapter
Removal Procedure
1. Ignition OFF.
Warning: Refer to Battery Disconnect Warning Service Precautions.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
3. Remove the engine cover. Refer to Intake Manifold Cover Replacement - Front Intake Manifold Cover Replacement - Front.
4. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement.
5. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement Fuel Pipe Shield Replacement.
Warning: Refer to Safety Glasses Warning Safety Glasses Warning.
Warning: Refer to Gasoline/Gasoline Vapors Warning Service Precautions.
Warning: Refer to Relieving Fuel Pressure Warning Service Precautions.
6. Relieve the high side fuel pressure. Refer to Fuel Pressure Relief Service and Repair.
7. Relieve the low side fuel pressure. Refer to Fuel Pressure Relief Service and Repair.
8. Remove the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.
9. Remove and discard the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement Fuel Feed Intermediate Pipe Replacement.
10. Remove the noise insulator from the fuel injection fuel rail assembly.
Note: Care should be taken not to damage the fuel injectors when removing the fuel injection fuel rails.
11. Remove the right bank fuel rail assembly from the cylinder head. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 2 Fuel Injection Fuel Rail Assembly Replacement - Bank 2.
12. Remove the left bank fuel rail assembly from the cylinder head. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 Fuel Injection Fuel Rail Assembly Replacement - Bank 1.
Note: Care should be taken not to damage the fuel injectors when removing the fuel injectors from the cylinder heads.
Note: Before removing the fuel injectors, note the orientation of the injectors and the injector wiring harness.
13. Detach the right bank fuel injector wiring harness electrical connector (2) from the engine wiring harness.
14. Using the J-37281-A - injector remover, release the right bank fuel injectors from the cylinder head.
15. Remove the right bank fuel injectors and wiring harness (1), as an assembly, from the cylinder head.
16. Detach the right bank fuel injectors from the right bank fuel injector wiring harness.
17. Detach the right bank fuel injectors from the fuel injector retainers on the right bank fuel injector wiring harness.
Note: Care should be taken not to damage the fuel injectors when removing the fuel injectors from the cylinder heads.
Note: Before removing the fuel injectors, note the orientation of the injectors and the injector wiring harness.
18. Detach the left bank fuel injector wiring harness electrical connector (2) from the engine wiring harness.
19. Using the injector remover J-37281-A - injector remover, release the left bank fuel injectors from the cylinder head.
20. Remove the left bank fuel injectors and wiring harness (1), as an assembly, from the cylinder head.
21. Detach the left bank fuel injectors from the left bank fuel injector wiring harness.
22. Detach the left bank fuel injectors from the fuel injector retainers on the left bank fuel injector wiring harness.
Installation Procedure
Note: Discard the fuel injector (4) if the fuel injector is damaged.
1. Remove and discard the following components from the fuel injectors:
* Upper O-ring Seal (1)
* Plastic Spacer (2)
* Retaining Ring (3)
Note: Use a suitable tool to cut the teflon seal.
* Teflon Seal (6)
* Circlip (7)
* Isolator Cup (5)
2. If required, clean the fuel injector bores using the injector bore and sleeve cleaning kit EN-47909 - injector bore and sleeve cleaning kit.
Note: Lubricate a NEW O-ring seal (1) with silicon free engine oil.
3. Install the following NEW components to the fuel injectors (4).
* Upper O-ring Seal (1)
* Plastic Spacer (2)
* Retaining Ring (3)
* Isolator Cup (5)
* Circlip (7)
Note: Use the procedure described below to install the teflon seal to the fuel injectors (4).
* Teflon Seal (6)
4. Install the fuel injector teflon seal installer of the EN-48266 - injector seal installer and sizer to the nozzle end of the fuel injector.
Note: DO NOT lubricate the NEW teflon seal.
5. Install a NEW teflon seal over the fuel injector teflon seal installer of the EN-48266 - injector seal installer and sizer.
6. Carefully push the NEW teflon seal along the fuel injector teflon seal installer of the EN-48266 - injector seal installer and sizer and into the groove of the fuel injector by hand.
7. Remove the fuel injector teflon seal installer of the EN-48266 - injector seal installer and sizer from the nozzle end of the fuel injector.
8. Install the teflon seal sizer of the EN-48266 - injector seal installer and sizer to the nozzle end of the fuel injector tip.
9. Using the teflon seal sizer of the EN-48266 - injector seal installer and sizer, resize the teflon seal.
10. Remove the teflon seal sizer of the EN-48266 - injector seal installer and sizer from the nozzle end of the fuel injector tip.
Caution:
Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring.
Note: Make sure that the fuel injector wiring harness is routed correctly. Failure to comply may cause damage to the wiring harness.
Note: Care should be taken not to damage the fuel injectors when installing the fuel injectors to the cylinder heads.
11. Attach the left bank fuel injectors to the fuel injector retainers on the left bank fuel injector wiring harness.
12. Connect the left bank fuel injectors to the left bank fuel injector wiring harness.
13. Install the left bank fuel injectors and wiring harness (1) as an assembly to the cylinder head.
14. Connect the left bank fuel injector wiring harness electrical connector (2) to the engine wiring harness.
Note: Make sure that the fuel injectors wiring harness is routed correctly. Failure to comply may cause damage to the wiring harness.
Note: Care should be taken not to damage the fuel injectors when installing the fuel injectors to the cylinder heads.
15. Install the right bank fuel injectors to the fuel injector retainers on the right bank fuel injector wiring harness.
16. Connect the right bank fuel injectors to the right bank fuel injector wiring harness.
17. Install the right bank fuel injectors and wiring harness (1) as an assembly to the cylinder head.
18. Connect the right bank fuel injector wiring harness electrical connector (2) to the engine wiring harness.
Note: Care should be taken not to damage the fuel injectors when installing the fuel injection fuel rails.
19. Install the left bank fuel rail assembly to the cylinder head. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 Fuel Injection Fuel Rail Assembly Replacement - Bank 1.
20. Install the right bank fuel rail assembly to the cylinder head. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 2 Fuel Injection Fuel Rail Assembly Replacement - Bank 2.
21. Install the noise insulator to the fuel injection fuel rail assembly.
22. Install a NEW fuel feed pipe. Refer to Fuel Feed Pipe Replacement Fuel Feed Pipe Replacement.
23. Install the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.
24. Install the fuel pipe shield. Refer to Fuel Pipe Shield Replacement Fuel Pipe Shield Replacement.
25. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement.
26. Install the engine cover. Refer to Intake Manifold Cover Replacement - Front Intake Manifold Cover Replacement - Front.
27. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.