Fuel Injector: Service and Repair

STANDARD PROCEDURE - INJECTOR CONNECTOR REMOVAL

Fig. 14 Fuel Injectors:

Fig. 15 Remove/Install Injector Conneector:

1. Disconnect electrical connectors at the fuel injectors (Fig. 14). To remove connector refer to (Fig. 15). Pull the red colored slider away from injector (1). While pulling the slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, make note of wiring location before removal.

REMOVAL - 2.0/2.4L

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

1. Release fuel system pressure. Refer to Fuel System Pressure Release procedure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Remove the engine cover or throttle control shield if equipped.

WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.

5. Disconnect fuel supply tube from rail. Refer to Quick-Connect Fittings.
6. Remove the Intake Manifold, refer to the Engine.
7. Disconnect electrical connectors from fuel injectors.

Fig. 16 Fuel Rail:

8. Remove bolts holding fuel rail (Fig. 16).
9. Remove the fuel rail and injectors.
10. Remove injectors from the fuel rail.

INSTALLATION - 2.0/2.4L
1. Install the fuel injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 Nm (8 ft. lbs.) (Fig. 16).
4. Attach electrical connectors to fuel injectors.
5. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery
6. Install Intake Manifold, refer to the Engine.
7. Install the engine cover or throttle control shield if equipped.
8. Install the negative battery cable.
9. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 3 ± 1 Nm (25 ± 5 in. lbs.) torque.