Fuel Injector: Service and Repair

REMOVAL PROCEDURE

CAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Remove the engine sight shield.

NOTE:
^ Remove the fuel pressure regulator in order to drain the excess fuel and in order to prevent fuel from entering the engine cylinders when the fuel injectors are removed for service. Flooded cylinders could result in engine damage.
^ Use care in removing the fuel injectors in order to prevent damage to the electrical connector pins on the injector and the nozzle. The fuel injector is serviced as a complete assembly only. Do not immerse the injector in a solvent bath.




3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
4. Remove the fuel rail assembly.




5. Remove the injector retainer clip (19).
6. Insert the fork of J 43013 fuel injector assemble removal tool behind the injector connector between the fuel rail pod and the 3 protruding retaining clip ledges. Use a prying motion while inserting the tool in order to force the injector out of the fuel rail pod.




7. Discard the injector retainer clip (1).
8. Remove the injector O-ring seals (2), (4) from both ends of the injector. Discard the O-ring seals.

INSTALLATION PROCEDURE

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




The fuel injector assembly (1) is stamped with a part number identification (2). A four digit build date code (3) indicates the month (4), day (5), year (6), and the shift (7) that built the injector.




1. Lubricate the new injector O-ring seals (2), (4) with clean engine oil.
2. Install the new injector O-ring seals on the injector.
3. Install a new retainer clip (1) on the injector.




4. Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket.




5. Install the fuel rail assembly.
6. Tighter the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks.
8.1. Turn the ignition ON for 2 seconds.
8.2. Turn the ignition OFF for 10 seconds.
8.3. Turn the ignition ON.
8.4. Inspect for fuel leaks.

NOTE: Refer to Fastener Notice in Cautions and Notices.




9. Install the engine sight shield.

Tighten
Tighten the engine sight shield bolts to 10 N.m (89 lb in)