Fuel Injector(S) Replacement

Fuel Rail Removal/Installation:

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. [1][2]Fuel System Pressure Relief Procedure
3. Remove the upper manifold plenum assembly.

a. Remove vacuum hoses, noting their positions for re-assembly.
b. Disconnect intake air duct from throttle body.
c. Disconnect EGR electrical connector and remove EGR valve.
d. Remove alternator brackets.
e. Remove ignition coil/module assembly.
f. Remove MAP sensor.
g. Remove upper manifold plenum.

4. Remove the fuel rail assembly.

CAUTION: Use care when removing fuel rail and injectors to avoid damaging electrical connector pins and injector nozzles. Fuel injectors cannot be disassembled. Service of injectors is limited to cleaning (with appropriate fuel injector cleaner) or replacement. Run cleaner through fuel inlet only, DO NOT immerse in cleaner.

Fuel Rail Assembly (Exploded View):

5. Remove injector retainer clips and discard.
6. Remove the injectors.
7. Remove the injector O-ring seals from both ends of injectors and discard. Save back-up O-rings for re-use.

PART IDENTIFICATION

MPFI Injector P/N Location:

Each injector is calibrated for a specific flow rate. When replacing fuel injectors, order replacements with the identical part numbers as the old injectors.

Reverse procedure for installation.

ASSEMBLY NOTES

1. Be sure to thoroughly clean old gasket material from all surfaces before installation.

CAUTION: Be careful when doing this so as not to damage machined surfaces. Because aluminum is such a soft metal, it is recommended that power tools NOT be used for cleaning machined aluminum surfaces.

1. Lubricate new injector O-ring seals with clean engine oil prior to installation.
2. Use new injector retaining clips and install clips with openings facing the injector electrical connectors.
3. Install injectors into the fuel rail sockets with the electrical connector facing forward.
^ Push in far enough to engage the retainer clip with the machined slots on the rail socket.
4. Tighten upper manifold plenum to lower manifold bolts to 18 lb.ft (25 Nm.)