Fuel Injector: Service and Repair

REMOVAL

1. Release pressure from fuel system at fuel pressure relief valve (schrader) on fuel rail assembly.

2. Remove upper intake manifold/throttle body assembly. Service and Repair

3. Disconnect fuel supply and fuel return lines using appropriate spring lock coupling disconnect tool. Remove fuel line safety clips.

Engine With Upper Intake Manifold Removed:

4. Carefully remove electrical harness connectors from individual injectors.

5. Disconnect vacuum line from fuel pressure regulator valve.

6. Remove four fuel injection supply manifold retaining bolts (2 per side).

Fuel Rail And Injectors:

7. Carefully disengage fuel injection supply manifold assembly from fuel injectors by lifting and gently rocking the manifold.

8. Grasping injector body, pull up while gently rocking injector from side to side.

Fuel Injector:

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

10. Inspect injector "plastic hat" (covering the injector pintle) and washer for signs of deterioration. Replace as required. If hat is missing, look for it in intake manifold.

INSTALLATION

1. Make sure injector caps are clean and free of dirt.

2. Lubricate top O-rings with clean engine oil.

NOTE: Never use silicone grease. It will clog the injectors.
3. Install the injectors into the fuel rail using a light, twisting, pushing motion.

4. Lubricate the lower O-rings with clean engine oil.

NOTE: Never use silicone grease. It will clog the injectors.

5. Carefully install fuel supply manifold assembly and injectors into the lower intake manifold, one side at a time. Push the fuel supply manifold down to make sure that all injector O-rings are fully seated in the fuel supply manifold cups and intake manifold.

6. While holding the fuel supply manifold assembly in place, install the two retaining bolts hand tight and then tighten the fuel supply manifold assembly retaining bolts to 8-12 Nm (6.0-8.0 lb ft).

7. Connect the fuel lines to the fuel rail.

8. Install the spring lock safety clips on the fuel rail connections.

9. Turn the ignition key ON for 2-3 seconds to presurize the fuel system, then check for leaks.

10. Install electrical harness connectors to injectors and the vacuum hose to the fuel pressure regulator.

11. Install upper intake manifold.

12. Install the fuel filler cap.

13. Start engine and warm to operating temperature. Check for leaks.