Fuel Injector: Service and Repair

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES.

1. Release fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove intake manifold plenum.
4. Lift Plenum off of engine. Cover intake manifold to prevent foreign material from entering engine.
5. Disconnect fuel supply tube quick connect fittings at the rear of intake manifold.
6. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
7. Remove electrical connectors from the fuel injectors.
8. Remove mounting bolts on both sides of fuel rail.
9. Lift fuel rail straight up off of cylinder head.
10. Remove retaining clips from fuel injectors at fuel rail.
11. Remove fuel injectors.

INSTALLATION
1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
2. Install retaining clips on fuel injectors.
3. Push injectors into fuel injector rail until clips are in the correct position.
4. Position fuel rail over cylinder head, and push rail into place. Tighten fuel rail mounting bolts to 12 Nm (105 in. lbs.) torque.
5. Connect fuel supply tube quick connect fittings at the rear of intake manifold.
6. Connect electrical connectors to fuel injectors.
7. Install intake manifold plenum
8. Connect the battery cable.
9. Use the DRB to check for leaks.