Fuel Injector: Service and Repair

REMOVAL
1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure.
Service and Repair

2. Remove intake manifold plenum.
3. Using Tool 6751, disconnect the fuel supply and return tubes from the fuel rail. Connect fuel gauge adapter 6631 to the fuel supply tube end of the rail. Connect fuel hose 6668 to the fuel return tube end of the rail.
4. Place the other end of fuel hose 6668 into an approved gasoline container.

Purging Fuel From Rail:

5. To purge fuel from rail, spray a maximum of 379 kPa (55 psi) of compressed air into the end of adapter 6631.
6. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
7. Remove electrical connector from injectors.
8. Remove the vacuum tube from the fuel pressure regulator.
9. Remove fuel rail mounting bolts,
10. Remove injector clamp screw.

Injector Clamp:

11. Slide the injector clamp toward the rear of the engine, then lift the clamp off of the rail.
12. Install fuel rail mounting bolts finger tight.

Fuel Injector Removal:

13. Using a thin flat screwdriver, pry the fuel injector out of the fuel rail.

Fuel Injector O-rings:

14. Ensure the upper and lower O-rings were removed with the injector. If not, remove them from the injector well in fuel rail.

INSTALLATION
If the fuel rail was removed to service the injectors, use a new gasket when installing the rail.

1. Lightly lubricate the O-rings with a couple drops of clean engine oil.

Fuel Injector Alignment:

2. When installing the injector, index the notch on the injector with the alignment tab on the fuel rail.
3. Index injector with tab in fuel rail. Install injector.
4. Remove fuel rail mounting bolts.
5. Install fuel injector clamps.
6. Tighten fuel rail mounting bolts to 11 Nm (100 in. lbs.) torque.
7. Install fuel injector clamp screw.
8. Attach electrical connectors to fuel injectors.
9. Install intake manifold plenum.