Fuel Injector: Service and Repair

REMOVAL

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. Remove the windshield wipers and the cowl panel.

Fig. 6 Fuel Supply Hose:

3. Disconnect the fuel disconnect line at the dashpanel (Fig. 6).
4. Connect fuel pressure tester adapter number #6539 to the fuel supply hose. Connect the other end to an approved gasoline container.
5. 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.
6. Disconnect the pressure tester adapter number #6539 from the fuel supply line.
7. Connect the fuel supply line back to the body fuel line at the dashpanel.

Fuel Injector Removal

Fig. 7 Fuel Injectors:

1. Disconnect electrical connector (Fig. 7). If injectors are not tagged with the appropriate cylinder number, use tape or a tag to identify cylinder number.

Fig. 8 Injector Holddown Clamp:

2. Remove injector holddown clamp (Fig. 8).

Fig. 9 Injector Removal:

Fig. 10 Fuel Injector O-rings:

3. Rotate injector until electrical connector faces intake manifold plenum. Use a screwdriver to pry the injector up out of the manifold (Fig. 9). Remove the upper and lower O-rings (Fig. 10).

INSTALLATION
Replace the injector O-rings if the original injector is reused. New injectors are supplied with new O-rings.
1. Apply a light coating of clean engine oil to the injector O-rings.
2. Push injector into intake manifold. Position injector with the electrical connector pointing towards the center of the intake manifold, except the right rear injector which orients to the rear 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.
5. Use the DRB Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.