Fuel Injector: Service and Repair

REMOVAL

1. Relieve the fuel line pressure.

Fuel Pump Relay:

2. Remove the negative battery cable.
3. Remove the intake plenum, as outlined in this section.
4. Remove the electrical connectors from the fuel injectors and the engine coolant temperature switch (ATX only).
5. Carefully bend the wire harness retainer brackets away from the wire harness and move the harness assembly away from the intake manifold.
6. Remove the fuel supply line from the pulsation damper.

Fuel Return Line:

7. Remove the fuel return line bracket from the intake manifold and remove clamp and return fuel line at the bracket.

Fuel Supply Manifold:

8. Remove the attaching bolts, spacers, insulators and the fuel rail with the injectors, pressure regulator and pulsation damper attached.
9. Remove the fuel injectors, grommets, and O-rings from the fuel rail.
10. Remove the O-rings from the injectors.

INSTALLATION

1. Position the grommets and new O-rings onto the fuel injectors. During installation apply a small amount of engine oil.
2. Position the insulators and fuel injectors into the intake manifold.

Fuel Injector:

3. Position the spacers and the fuel rail on the injectors.
4. Install the spacers and attaching nuts to the fuel rail and torque the attaching bolts. Refer to SPECIFICATIONS.
5. Install the electrical connectors to the fuel injectors and to the engine coolant temperature switch (ATX only).
6. Install the fuel return line brackets onto the intake manifold and install the return fuel line at the bracket and secure the clamp.
7. Install the fuel supply line onto the pulsation damper and secure with clamp.
8. Install the intake plenum.

Intake Manifold Components:

9. Install the wiring harness into the retainer brackets and carefully bend the brackets toward the wire harness.
10. Install the negative battery cable.