Fuel Injector: Service and Repair

REMOVAL

1. Remove the fuel cap and release the system pressure by opening the fuel pressure relief valve using EFI pressure gauge T80L-9974-B or equivalent.

2. Remove the upper intake manifold assembly.

3. Carefully remove the fuel injector electrical connectors.

4. Remove the spring lock coupling retainer clips from the fuel inlet and return fittings.

5. Disconnect the push connect fittings at the fuel supply manifold and fuel return lines.

6. Remove the two fuel supply manifold retaining bolts.

7. Carefully disengage manifold and fuel injectors from engine and remove fuel rail and injectors.

Fuel Injector:

8. Pull up the fuel injector while gently rocking it from side to side.

9. Inspect the injector O-rings (two per injector) for signs of deterioration. Replace as required.

INSTALLATION

Fuel Injector:

1. Replace and lubricate the two injector O-rings on each injector with clean engine oil.

NOTE: Never use silicone grease, it will clog the injectors. Make sure the injector end caps are clean and free of contamination.

2. Install the fuel injector supply manifold and injectors into the intake manifold.

3. Push the fuel rail down to make sure that all the fuel injector O-rings are fully seated in the fuel rail and intake manifold.

4. While holding the fuel rail assembly down, install and tighten the two retaining bolts to 15-22 ft lb (20-30 Nm).

5. Connect the fuel supply and return lines to the fuel supply manifold.

6. Attach the spring lock coupling retainer clips on the fuel inlet and return fittings.

7. After the fuel rail assembly has been installed and before the fuel injector wire connectors have been connected, turn the key to the ON position, pressurizing the fuel system.

8. Check for fuel leaks where the injectors are installed in the fuel rail.

9. Install the upper intake manifold.

10. Install the cap on the fuel pressure relief valve, if removed.

11. Connect the fuel injector electrical connectors. Start the engine and let run for two minutes.

12. Turn the engine OFF and check for leaks.