Fuel Injector: Service and Repair
FUEL INJECTOR REPLACEMENTREMOVAL PROCEDURE
CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions.
NOTE: Upon disassembly of the fuel system components, use a shop towel in order to absorb any liquid fuel that is released. A significant amount of liquid fuel entering an engine cylinder can damage internal engine parts upon the compression stroke.
1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the throttle body assembly.
3. Disconnect the fuel injector electrical connectors.
4. Remove the fastener securing the fuel supply pipe (5) and the fuel return pipe (2) to the engine.
5. Disconnect the vacuum hose (1) to the fuel pressure regulator.
6. Disconnect the fuel return hose (3) from the fuel pressure regulator. Use a shop towel in order to catch any remaining fuel that may leak.
7. Remove the union bolt (3) that secures the fuel supply pipe (2) to the fuel rail. Use a shop towel in order to catch any remaining fuel that may leak.
8. Remove the two union bolts (2) securing the fuel rail crossover pipe (3) at the rear of the fuel rails. Use a shop towel in order to catch any remaining fuel that may leak.
9. Remove the two hold down bolts (1) from the left fuel rail (2). Use a shop towel in order to catch any remaining fuel that may leak.
10. Remove the left fuel rail (2) and fuel injectors.
11. Remove the two hold down bolts (4) from the right fuel rail (3). Use a shop towel in order to catch any remaining fuel that may leak.
12. Remove the right fuel rail (3) and fuel injectors. Use a shop towel in order to catch any remaining fuel that may leak.
13. Remove the fuel injectors (3) from the fuel rail as necessary.
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. Apply a thin coat of motor oil to the fuel injector O-rings (1).
2. Install a fuel injector O-ring (1) with a collar (2) to each fuel injector (3).
3. Install each fuel injector (3) 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.
4. Prepare each fuel rail assembly for installation, by ensuring that the cushions (4) are properly located in the fuel injector cavity of the intake manifold. Replace any missing or damaged cushions as necessary.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Install the left fuel rail to the intake manifold with two bolts and two spacers (1).
Tighten
Tighten the bolts to 23 N.m (16.5 lb ft).
6. Install the right fuel rail to the intake manifold with two bolts and two spacers (1).
Tighten
Tighten the bolts to 23 N.m (16.5 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.
7. Verify that the fuel injectors rotate smoothly and freely.
8. Install the fuel rail crossover pipe (3) to the fuel rails, using new washers (1,4) arid securing with the two union bolts (2).
Tighten
Tighten the union bolts to 30 N.m (22 lb ft).
9. Install the fuel supply pipe (2) to the right side fuel rail with two new washers (1, 4).
10. Secure the fuel supply pipe (2) with the union bolt (3).
Tighten
Tighten the union bolt to 30 N.m (22 lb ft).
11. Connect the fuel return hose (3) to the fuel pressure regulator.
12. Secure the fuel supply pipe (5) and the fuel return pipe (2) to the engine with the bracket and bolt.
Tighten
Tighten the bolt to 10 N.m (89 lb in). Connect the fuel injector electrical connectors.
13. Connect the battery.
14. Turn ON the ignition, leaving the engine OFF.
15. Turn ON the fuel pump with the scan tool.
16. Check for fuel leaks and repair as necessary.
17. Install the throttle body assembly.