Fuel Injector: Service and Repair

Fuel Injector and Fuel Rail Replacement

Removal Procedure

Warning: Refer to Gasoline/Gasoline Vapors Warning (Service Precautions).

Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Fuel Pressure Relief).
2. Remove the upper intake manifold with the lower intake manifold. Refer to Upper Intake Manifold Replacement (Service and Repair).




3. Remove the fuel pipe retaining clip (1).




4. Disconnect the fuel feed line pipe (2) from the fuel injector rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
Warning: Refer to Safety Glasses and Compressed Air Warning (Safety Glasses and Compressed Air Warning).

5. Use compressed air in order to remove debris from the area where the fuel injectors enter the intake manifold.




6. Remove the fuel rail to lower inlet manifold retaining bolts (1).

Caution:
* Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
* Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

7. Remove the fuel rail (2) and the fuel injectors (3) from the manifold.




8. Disengage the fuel injector electrical connector lock (1).




9. Disconnect the fuel injector electrical connector (1) from the fuel injector (2).




10. Remove the fuel injector retainer clip (1) from the fuel rail (2).




11. Remove the fuel injector (1) from the fuel rail (2).
12. Remove and discard the fuel injector seals.

Installation Procedure

1. Install NEW fuel injector seals.




2. Install the fuel injector (1) to the fuel rail (2).




3. Install the fuel injector retainer clip (1) to the fuel rail (2).




4. Install the fuel injector electrical connector (1) to the fuel injector (2).
5. Engage the fuel injector electrical connector lock.




6. Install the fuel rail (2) with the fuel injectors (1) to the lower manifold.

Caution: Refer to Fastener Caution (Fastener Caution).

7. Install the fuel rail to lower manifold retaining bolts (1) and tighten to 10 Nm (89 lb in).




8. Connect the fuel feed line (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




9. Install the fuel pipe retaining clip.
10. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement (Service and Repair).