Fuel Injector: Service and Repair

WARNING: Do not smoke while working on the fuel system. Keep open flames or sparks away from the work area. Make sure the engine is OFF while relieving fuel pressure.

1. Relieve the fuel pressure.
a. Disconnect the negative battery cable.
b. Remove the fuel tank filler cap.
c. Use a box end wrench on the 6mm service bolt at the top of the fuel filter, while holding the special banjo bolt with another wrench.

Fig. 53 Bleeding Off Fuel Pressure:

d. Place a rag or shop towel over the 6mm service bolt and SLOWLY loosen the 6mm service bolt one complete turn.
2. Disconnect the electrical connector from each injector.
3. Disconnect the vacuum hose and fuel return hose from the pressure regulator.

NOTE: Place a rag or shop towel over the hoses before disconnecting them, to absorb excess fuel run-off.

4. Loosen the retainer nuts on the fuel pipe and harness holder.

Fig. 27 Fuel Injector/Fuel Pipe Assembly (Exploded View):

5. disconnect the fuel pipe.
6. Remove the injectors from the intake manifold.
7. Slide new cushion rings onto the injectors.
8. Coat new O-rings with clean engine oil and put them on the injectors.
9. Insert the injectors into the the fuel pipe first.
10. Coat new seal rings with clean engine oil and press them into the intake manifold.

Fig. 28 Fuel Injector Installation:

Fig. 29 Fuel Injector alignment:

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

11. Align the center line on the connector with the mark on the fuel pipe.
12. Install and tighten the retainer nuts.
13. Connect the vacuum hose and fuel return hose to the pressure regulator.
14. Install the electrical connectors on the injectors.
15. Turn the ignition switch ON but DO NOT start engine. After the fuel pump runs for approximately 2 seconds, the fuel pressure in the fuel line increases. Repeat two or three times, and check for fuel leaks.