Fuel Injector: Service and Repair

The fuel Injectors and injector inserts are removed and installed by removing the fuel rail. Although the entire assembly of fuel rail and injectors can be removed as a unit, it may be easier to first remove the fuel rail from the injectors and then remove the individual injectors from the engine.

To remove injector fuel rail and injectors:

Digifant II Fuel Rail Assembly:

1. Disconnect the negative (-) battery terminal, and disconnect the main electrical connector at the fuel rail.

Idle Stabilization Diagram:

2. Remove the idle stabilizer valve. Disconnect the electrical connector, then remove the hoses and mounting bracket.
3. Loosen the hose clamp and disconnect the crankcase ventilation hose from the throttle body. Swing the hose out of the way.
4. Remove the vacuum hose and the blue fuel return hose from the fuel pressure regulator.

WARNING: Fuel will be expelled. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.

Digifant Fuel Delivery Components:

5. Remove two (2) Phillips-head screws and remove the pressure regulator. Using a 6mm hex wrench, remove the socket-head mounting bolt and the pressure regulator mounting bracket.

NOTE: It may be easier to remove the intake air hose to gain better access to the pressure regulator. To remove the hose, remove the clamps and pull the hose from the engine. Cover the openings with a clean, lint-free cloth.

6. Using a 5mm hex wrench, remove the two (2) socket-head fuel rail mounting bolts. Pry off the injector mounting clips using a small, flat-bladed screwdriver.
7. Remove the black fuel supply line from the connection atop the fuel rail.

WARNING: Fuel will be expelled. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.

8. Disconnect the injector electrical connectors and pull the fuel rail from the injectors.

NOTE: If necessary, cut the wire ties which secure the wiring harness to the fuel rail, and disconnect the connectors after removing the fuel rail.

9. Remove each injector from its insert.
10. Remove the injector inserts using a 10mm hex wrench.
11. Installation is the reverse of removal.
12. Replace the injector and pressure regulator O-rings.
13. Clean the threads of the injector inserts, apply thread locking compound to the threads, and install the inserts.
14. Torque the injector inserts to:

15 ft.lb. (20 Nm)

15. Be sure the injector's electrical connections are aligned correctly and that the injectors are fully seated prior to installing the fuel rail.
16. Use new hose clamps on the fuel supply and return lines.
17. Torque the fuel rail mounting bolts to:

7 ft.lb. (10 Nm)

18. Torque the fuel pressure regulator mounting bolts to:

11 ft.lb. (15 Nm)

19. Mount the idle stabilizer valve and torque the mounting bolts to:

7 ft.lb. (10 Nm)

20. Reconnect the main electrical connector at the fuel rail and the negative (-) battery terminal.
21. START engine and check for any fuel leaks at the fuel injectors, fuel rail and pressure regulator, repair leaks immediately.