Fuel Injector: Service and Repair

FUEL INJECTOR REPLACEMENT


WARNING:

Do not smoke while working on the fuel system.
Keep open flame away from the work area.
Be sure to relieve fuel pressure with the engine off.

1. Disconnect the negative battery cable from the battery.

NOTE:
Before disconnecting fuel pipes or hoses, relieve pressure in the system by removing the gas cap and proceeding to step 2.

Fig. 45 Relieving fuel Pressure:

2. Use a box end wrench on the 6 mm service bolt on top of the fuel filter, while holding the special banjo bolt with another wrench.
3. Place a rag or shop towel over the 6 mm service bolt and wrenches.
4. Slowly loosen the 6 mm service bolt one complete turn.

NOTE:
Always replace the washer between the service bolt and the special banjo bolt, whenever the service bolt is loosened to relieve fuel pressure.
Replace all washers whenever the bolts are removed to disassemble parts.


5. Disconnect the electrical connectors from the injectors.
6. Disconnect the vacuum hose and fuel return hose from the pressure regulator.

NOTE:
Place a rag or shop towel over the hose and tube before disconnecting them.

7. Loosen the retainer nuts on the fuel pipe and remove the fuel line.
8. Disconnect the fuel pipe.
9. Remove the injectors from the intake manifold.

Fig. 55 Injector And Fuel Rail Assembly:

10. Slide new cushion rings onto the injectors.
11. Coat new O-rings with clean engine oil and put them on the injectors.
12. Insert the injectors into the fuel pipe first.
13. Coat the new seal rings with clean engine oil and press them into the intake manifold.
14. Install the injectors and fuel pipe assembly into the manifold.

CAUTION:
To prevent damage to the O-ring, install the injectors in the fuel pipe first. Then install them into the intake manifold.

Fig. 56 Installing Fuel Injectors:

Fig. 57 Fuel Injector Alignment:

15. Align the center line on the connector with the mark on the fuel pipe.
16. Install and tighten the retainer nuts and the fuel line.
17. Connect the vacuum hose and the fuel return hose to the pressure regulator.
18. Install the electrical connectors onto the injectors.
19. Turn the ignition switch ON but do not operate the starter. After the fuel pump runs for approximately two seconds, the fuel pressure rises. Repeat this two or three times, then check for fuel leaks.