Fuel Injector: Service and Repair
FUEL RAIL AND INJECTOR(S) REPLACEMENTTOOLS REQUIRED
^ J 37088 Fuel Line Disconnect Set
^ J 44095 Fuel Pressure Adapter Fitting
^ SA9127E Gauge Bar Set
REMOVAL
CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL OR EVAP SYSTEM IS TAKING PLACE. ANYTIME WORK IS BEING DONE ON THE FUEL SYSTEM, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.
1. Disconnect negative battery cable.
2. Loosen clamp at air cleaner and throttle body assembly.
3. Remove attachment bolts from outlet resonator/duct assembly.
4. Remove outlet resonator/duct assembly.
5. Remove outlet resonator/duct assembly bracket from manifold.
CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING TO COLLECT FUEL. PLACE CLOTH IN AN APPROVED CONTAINER.
6. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief" procedure in the Fuel System.
7. Disconnect Gauge Bar Set SA9127E (or equivalent) and Fuel Pressure Adapter Fitting J 44095 (or equivalent) after pressure has been relieved.
8. Disconnect fuel transfer line at quick connect from fuel line using Fuel Line Disconnect Set J 37088 (or equivalent) (blue tool).
NOTE: To avoid thread damage, only use hand tools when working with the intake manifold. Do not over tighten bolts on manifold.
9. Lift and support intake manifold assembly. (Refer to "Intake Manifold Lift and Support Procedure - L81" in the Induction System.)
10. Disconnect electrical connectors at fuel injectors.
11. Remove fuel rail line bracket bolt.
12. Reposition intake manifold onto cylinder head.
13. Remove intake manifold cover bolts and cover.
14. Remove vacuum chamber bolts and lift chamber.
15. Disconnect vacuum line from vacuum chamber.
16. Remove vacuum chamber.
17. Disconnect fuel rail bracket bolt at rear of camshaft cover.
IMPORTANT: Support fuel rail lines with open-end wrench while loosening the transfer line fittings.
18. Loosen transfer line fittings.
19. Remove fuel rail attachment bolts to manifold.
20. Remove front fuel rail assembly with injector from intake manifold by lifting upward.
21. Remove rear (Curved) fuel rail assembly with injectors from intake manifold by lifting upward.
NOTE:
^ When cleaning or servicing the fuel rail, care should be taken to ensure that the fuel rail surfaces that mate to the fuel injector O-ring seals are not scratched.
^ Whenever the fuel injector is removed from the fuel rail, upper and lower O-ring seals must be replaced.
IMPORTANT: If fuel rail is being replaced, remove all injectors and replace all O-rings, otherwise each injector can be removed individually.
22. Remove fuel injector(s) retaining clips.
23. Remove fuel injector(s) from fuel rail.
24. Remove and discard all injector O-ring seals by using a small pick.
INSTALLATION
1. Install new upper and lower O-ring seals to injector(s).
2. Install clip to injector, aligning tab on injector to notch in clip.
IMPORTANT: Injector is fully seated when tabs are aligned and clip is engaged on fuel rail. An audible click should be heard upon engagement. Verify fuel rail port is engaged on each side of the clip.
3. Align notch in clip to tab on fuel rail, and Install injector with clip assembly to fuel rail assembly.
4. Verify injector(s) is fully seated.
IMPORTANT: Rear fuel injector rail (curved) must be installed before front rail assembly.
5. Install rear fuel injector assembly (curved) into position. Lightly press on fuel rail to seat fuel injectors into injector ports.
6. Install front fuel injector assembly into position. Lightly press on fuel rail to seat fuel injectors onto injector ports.
7. Install fuel rail to manifold bolts.
Torque:
Fuel Rail-to-Manifold Bolts - L81: 7.5 N.m (66 in-lbs)
NOTE: Support fuel rail lines with open-end wrench while tightening the transfer line fittings.
8. Connect fuel line quick connects.
Torque:
Transfer Line Fitting-to-Fuel Rail - L81: 15 N.m (11 ft-lbs)
9. Connect fuel rail bracket bolt at rear of intake manifold.
Torque:
Fuel Line Bracket Bolt L81: 4.4 N.m (39 in-lbs)
10. Verify gasket is positioned properly on vacuum chamber.
11. Install vacuum chamber to intake manifold.
Torque:
Vacuum Chamber-to-Intake Manifold Bolts - L81: 2 N.m (18 in-lbs)
12. Install vacuum line to vacuum chamber port.
13. Install sleeve seals to intake manifold top cover
14. Install top cover into position and tighten upper intake manifold bolts.
Torque:
Intake Manifold Top Cover To Manifold Bolts - L81: 4 N.m (35 in-lbs)
15. Raise intake manifold up and connect electrical connectors to fuel injectors.
16. Attach fuel line bracket to manifold
Torque:
Fuel Line Bracket-to-Manifold Bolt: 6 N.m (47 in-lbs)
17. Install intake manifold assembly.
18. Install outlet resonator duct assembly bracket to intake manifold.
Torque:
Outlet Resonator/Duct Assembly Bracket-to-Intake Manifold Nuts - L81: 5 N.m (44 in-lbs)
19. Install outlet resonator duct assembly into position.
20. Tighten clamp at throttle body assembly.
21. Position outlet resonator duct assembly to support bracket and install bolts.
Torque:
Outlet Resonator/Duct Assembly-to-Support Bracket Bolts - L81: 10 N.m (89 in-lbs)
22. Tighten clamp at air cleaner assembly.
23. Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)