Fuel Injector(S) Replacement

Injector Part Number Location:

NOTICE:
^ Always remove the fuel pressure regulator to drain excess fuel, and to prevent fuel from entering engine cylinders when injectors are removed for service. Flooded cylinders could result in engine damage.
^ Use care in removing injectors to prevent damage to the electrical connector pins on the injector and the nozzle. The fuel injector is serviced as a complete assembly only. Since it is an electrical component, do not soak it in cleaner.

Removal

1. Relieve fuel system pressure.
^ Refer to the "Fuel Pressure Relief Procedure."
2. Disconnect negative battery cable.
3. Remove upper manifold assembly.

CAUTION: To reduce the chance of personal injury, cover regulator and fuel line fittings with a shop towel before disconnecting to catch any fuel that may leak out. Place the towel in an approved container after disconnect is completed.

4. Remove fuel return line retaining bracket nut.
5. Remove fuel return line retaining bracket.
^ Move return line away from regulator.
6. Remove pressure regulator assembly.
^ Refer to "Fuel Pressure Regulator."

NOTICE:
^ To prevent damage to injector retaining bracket and/or injectors, do not try to remove injectors by lifting up the injector retaining bracket while injectors still are installed in bracket slots.
^ Do Not attempt to remove bracket without first removing fuel pressure regulator.

7. Remove injector retainer bracket attaching screws.
8. Remove injector retainer bracket.
^ Carefully slide bracket off to clear injector slots and regulator.
9. Disconnect injector electrical connector(s).

CAUTION: To reduce the risk of fire and personal injury, verify that the lower (small) O-ring of each injector does not remain in the lower manifold. If the O-ring is not removed with the injector, the replacement injector, with new O-rings, will not seat properly in the injector socket and could cause a fuel leak.

10. Remove fuel injector(s).
^ Discard O-ring seals.

Important: When ordering new fuel injectors, be sure to order the correct injector for the application being serviced.

NOTICE: Cover injector sockets to prevent dirt and other contaminants from entering into open fuel passages.

Installation

1. Lubricate new injector O-ring seals with clean engine oil, and install on injector assembly.
^ See "CAUTION" statement above.
2. Install bottom feed multiport injector assembly into lower manifold injector socket with electrical connectors facing inward.
3. Install injector retainer bracket.
^ Carefully install bracket so that injector retaining slots and regulator are aligned with bracket slots.
4. Reconnect injector electrical connectors.
5. Install pressure regulator assembly.
^ Refer to "Fuel Pressure Regulator."
6. Install injector retainer bracket attaching screws. Tighten injector retainer bracket attaching screws to 3.5 N-m (31 lb. in.).
7. Install upper manifold assembly.
8. Install accelerator cable bracket with attaching bolts/nuts. Tighten cable bracket nut to 25 N-m (18 lb.ft.). Tighten accelerator cable bracket bolts to 25 N-m (18 lb. ft.).
9. Tighten fuel filler cap.
10. Reconnect negative battery cable.

Inspection
^ Turn ignition switch to the "ON" position for two seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position and check for fuel leaks.

11. Install air intake duct.