Fuel Injector: Service and Repair
TOOLS REQUIRED^ J 34730 Fuel Pressure Gauge
^ J 43013 Fuel Injector Removal Tool
REMOVAL PROCEDURE
NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
IMPORTANT: The fuel injector is serviced as a complete assembly only. If the fuel injectors are found to be leaking the engine oil may be contaminated with fuel.
1. Relieve the fuel pressure. Refer to the Fuel Pressure Relief Procedure. Service and Repair
2. Remove the fuel injector electrical connector (1) from the fuel injector (2).
IMPORTANT: It may be necessary to remove the fuel rail from the intake manifold to allow increased fuel rail movement for injector access.
3. Remove the bolts from the fuel rail.
4. Raise the fuel injectors from the intake manifold with J43013.
IMPORTANT: Store the fuel rail assembly in a clean secure location away from heat sources.
5. Lift the fuel rail and remove the fuel rail.
IMPORTANT: It may be necessary to release the adjacent injector(s) from the intake manifold to allow increased fuel rail movement for injector access.
6. Spread the injector retainer clip (1) to release injector from fuel rail (3).
7. Remove the fuel injector assembly.
8. Remove the fuel injector upper O-ring (3).
9. Remove the fuel injector lower O-ring (2).
10. Discard the injector O-ring seals.
INSTALLATION PROCEDURE
CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.
IMPORTANT: Fuel injector O-rings should always be replaced whenever fuel injectors are serviced.
Each fuel injector is calibrated for a specific flow rate. Be sure to use the correct part number when ordering replacement fuel injectors. Be sure to reinstall the correct O-ring for fuel injector. It the sealing O-ring is not seated properly, a vacuum leak is possible and driveability complaints may occur.
1. Lubricate the new upper (3) and lower (2) O-rings with clean engine oil.
2. Install the new upper and lower injector O-rings on the fuel injector.
3. Install the fuel rail assembly on to the intake manifold until the fuel injectors are fully seated.
4. Spread the injector retainer clip (1) to install injector to the fuel rail (3).
NOTE: Refer to Fastener Notice in Service and Precautions.
5. Install the bolts to the fuel rail assembly.
Tighten
Tighten the to bolts to 10 N.m (88 lb in).
6. Snap the fuel rail down on to intake manifold.
7. Install the fuel injector electrical connector (1) to the fuel injector (2).
8. Add fuel to the fuel tank.
9. Tighten the fuel filler cap.
CAUTION: Refer to Battery Disconnect Caution in Service and Precautions.
10. Install the negative battery cable.
10.1. Turn ON the ignition to position for 2 seconds.
10.2. Turn OFF the ignition for 10 seconds.
10.3. Turn ON the ignition.
10.4. Check for fuel leaks.
11. Install the fuel injector sight shield (1) to the engine.
12. Install the fuel injector sight shield nuts (2).
Tighten
Tighten the nuts 3 N.m (27 lb in).