Fuel Injector: Service and Repair

Fig. 13 Fuel Supply Hose:

NOTE: Remove all fuel from the fuel passage before servicing the injectors. The bottom of the fuel injector sits in the fuel passage. If the passage is not purged of fuel, the passage will drain into the cylinder when the injector is removed.

EMPTYING FUEL PASSAGE
1. Perform Fuel System Pressure Release Procedure. Leave fuel hose C-4799-1 attached to the fuel pressure test port.
2. Raise vehicle on hoist.
3. Disconnect fuel supply hose from the outlet side of the fuel filter (Fig. 13).
4. Connect fuel pressure tester adapter number 6539 to the fuel supply hose.
- Connect the other end to an approved gasoline container.
5. Lower vehicle.
6. Spray a maximum of 69 kPa (10 psi) compressed air into the open end of fuel hose C-4799-1 at the fuel pressure test port.
- Stop spraying compressed air when the fuel passage empties through the fuel supply hose (at the filter).

Fig. 14 Fuel Injectors:

FUEL INJECTOR REMOVAL
1. Disconnect electrical connector (Fig. 14).
- If injectors are not tagged with the appropriate cylinder number, use tape or a tag to identify cylinder number.

Fig. 15 Injector Holddown Clamp:

2. Remove injector holddown clamp (Fig. 15).
3. Rotate injector until electrical connector faces intake manifold plenum.

Fig. 16 Injector Removal:

- Use a screwdriver to pry the injector up out of the manifold (Fig. 16).

Fig. 17 Fuel Injector 0-rings:

- Remove the upper and lower 0-rings (Fig. 17).

NOTE: Replace the injector O-rings if the original injector is reused. New injectors are supplied with new O-rings.

FUEL INJECTOR INSTALLATION
1. Apply a light coating of clean engine oil to the injector 0-rings.
2. Push injector into intake manifold.
- Position injector with the electrical connector pointing towards the center of the intake manifold.
3. Install injector holddown clamp and screw.
- Tighten holddown clamp to 11 Nm (95 in. lbs.) torque.
4. Connect electrical connector to injector.

CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position.

5. Use the DRB Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.