Fuel Injector: Service and Repair

Remove
1. Disconnect battery negative lead.
2. Depressurise fuel system.Depressurizing Fuel System
3. Release plenum chamber and place aside.







4. Disconnect purge hose, crankcase breather hose, servo vacuum hose and fuel regulator hose from ram housing.
5. Remove 6 bolts securing ram housing to inlet manifold.
6. Place small packing block on inlet manifold. Lever between packing block and ram pipe housing to break seal.


CAUTION: Do not lever against fuel rail.


7. Remove ram housing.
8. Place cloth over inlet manifold to prevent ingress of foreign matter.







9. Disconnect 8 injector multiplugs.
10. Disconnect fuel temperature sensor multiplug.
11. Position cloth around fuel feed pipe union to absorb fuel spillage.
12. Disconnect fuel feed pipe from fuel rail.
13. Plug fuel pipe and rail.
14. Slacken clip securing fuel return hose.
15. Disconnect hose, plug return hose and rail. Remove cloth.
16. Remove 6 nuts securing fuel rail and ignition coil bracket to inlet manifold.
17. Release ignition coil bracket from inlet manifold studs. Place aside.
18. Release fuel rail and injectors from inlet manifold. Do not carry out further dismantling if component is removed for access only.
19. Remove fuel rail and injectors.







20. Remove 2 bolts securing fuel pressure regulator to fuel rail.
21. Remove pressure regulator assembly.
22. Remove 'O ring from fuel pressure regulator and discard.
23. Remove 8 clips securing injectors to fuel rail.
24. Remove injectors from fuel rail.
25. Remove 2 'O' rings from each injector and discard.

Refit
26. Ensure mating surfaces between inlet manifold and ram pipe housing are clean.
27. Ensure all locations in fuel rail and inlet manifold are clean.
28. Lubricate and fit new 'O' rings to injectors and fuel pressure regulator.
29. Fit fuel pressure regulator to fuel rail. Secure with bolts. Tighten to 10 Nm.
30. Fit injectors to fuel rail. Secure with clips.
31. Position fuel rail to inlet manifold. Engage injectors, one bank at a time.
32. Position ignition coil bracket on inlet manifold studs.
33. Secure ignition coil bracket and fuel rail to inlet manifold with nuts. Tighten to 8 Nm.
34. Remove plugs from fuel feed and return pipes and rail.
35. Connect hose and tighten clip.
36. Clean feed pipe union and connect fuel feed pipe to fuel rail. Tighten union to 16 Nm.
37. Connect multiplugs to fuel injectors and fuel temperature sensor.
38. Remove cloth from inlet manifold.
39. Apply a thin, uniform coating of Loctite 577 sealant to mating face of inlet manifold.
40. Fit ram housing to inlet manifold. Secure with bolts. Tighten to 24 Nm.
41. Connect purge hose, crankcase breather hose, servo and pressure regulator vacuum hoses to ram housing.
42. Fit plenum chamber.
43. Reconnect battery negative lead.
44. Start engine. Check for leaks around fuel rail and injectors.