Fuel Injector: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
J 43178 Prizm Fuel Line Quick Connect Separator

IMPORTANT:
^ Use care in removing the fuel injectors to prevent damage to the electrical connectors pins on the injector and to prevent damage to the nozzle. The fuel injector is an electrical component. Do Not immerse the injector in any type of cleaner.
^ The engine oil may be contaminated with fuel if the fuel injectors are leaking.




1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Disconnect the four spark plug wires from the two ignition coils.
3. Disconnect the PCV and breather hoses from the valve cover.
4. Remove the nut and the accelerator cable bracket from the cylinder head.




5. Remove the two nuts (1) from the wire harness cover plate.
6. Remove the one bolt (2) and wire harness cover plate (3) from the engine.




7. Disconnect the 4 fuel injector electrical connectors (1).
8. Remove the two bolts (2) and pull back the wiring harness (3).
9. Remove the fuel feed hose quick connect coupling cover.




10. Disconnect the fuel feed hose quick connect fitting from the fuel feed pipe of the fuel rail using the J 43178 Prizm Fuel Line Quick Connect Separator. Use a shop towel to catch any remaining fuel that may leak.




11. Remove the one fuel rail inlet pipe hold down bolt (1).




12. Remove the two fuel rail hold down bolts (1).
13. Remove the fuel rail (6) with the fuel injectors from the cylinder head.
14. Remove the two fuel rail spacers (2) from the cylinder head.
15. Remove the fuel injectors (4) with O-ring (5) and grommet (3) from the fuel rail.

INSTALLATION PROCEDURE

IMPORTANT: Replace the fuel injector O-rings when servicing the fuel injectors. Take care not to damage the O-rings during installation.




1. Install the fuel injectors (4) and grommets (3) with new O-rings (5) to the fuel rail.
2. Install the fuel rail spacers (2) to the cylinder head.

IMPORTANT: Make sure that the fuel injectors rotate smoothly. Check for incorrectly installed fuel injector O-rings and replace the O-rings if necessary.

3. Install the fuel rail (6) with the fuel injectors to the cylinder head.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Secure the fuel rail (6) with the two fuel rail bolts (1).

Tighten
Tighten the fuel rail bolts to 18.5 N.m (13 lb ft).




5. Install the one fuel rail inlet pipe hold down bolt (1).

Tighten
Tighten the fuel rail inlet pipe hold down bolt to 9 N.m (79 lb in).




6. Connect the fuel feed hose quick connect fitting (1) to the fuel feed pipe (2) of the fuel rail.
7. Install the fuel feed hose quick connect coupling cover.




8. Install the wiring harness (3) to the cylinder head.
9. Secure the wiring harness with the two bolts (2).

Tighten
Tighten the two bolts to 8 N.m (71 lb ft).

10. Connect the 4 fuel injector electrical connectors (1).




11. Install the wire harness cover plate (3) with the one bolt (2) to the engine.

Tighten
Tighten the cover plate bolt to 8 N.m (71 lb in).

12. Secure the wire harness cover plate (3) to the engine with the two nuts (1).

Tighten
Tighten the two nuts to 8 N.m (71 lb in).




13. Install the accelerator cable bracket to the stud on the cylinder head and secure with the nut.

Tighten
Tighten the bracket nut on the stud to 8 N.m (71 lb in).

14. Connect the PCV and breather hoses to the valve cover.
15. Connect the four spark plug wires to the two ignition coils.
16. Connect the negative battery cable.

Tighten
Tighten the negative battery cable terminal retainer to 15 N.m (11 lb ft).

17. Turn ON the ignition in order to pressurize the fuel system.
18. Turn OFF the ignition.
19. Check for any fuel leaks.