Fuel Injector: Service and Repair

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY.

1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet tube.
3. Release the fuel pressure.
4. Disconnect the fuel supply hose spring lock coupling.
5. Remove the Exhaust Gas Recirculation (EGR) valve and the exhaust manifold-to-EGR valve tube.







6. Remove the throttle body and spacer assembly.







7. Disconnect the vacuum hose.







8. Disconnect the fuel pulse damper electrical connector and the vacuum hose.







9. Disconnect the eight fuel injector electrical connectors.

NOTE: RH shown, LH similar.







10. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places.







11. Remove the fuel supply manifold mounting studs.







12. Remove the fuel supply manifold and fuel injectors as an assembly.







13. Remove the anti-rotation clips and the fuel injectors from the fuel supply manifold.


INSTALLATION







1. To install, reverse the removal procedure.

NOTE:
^ Always install new 0-rings.
^ Lubricate the 0-rings with clean engine oil to aid installation.
^ Make sure the anti-rotation clips are installed.