Fuel Injectors

REMOVAL & INSTALLATION

1. Disconnect the negative battery cable.
2. Relieve the fuel pressure.

   Fig. 1: Exploded view of the fuel injectors and related components necessary for removal

   CAUTION
   Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

3. Remove the right engine service hole cover.
4. Disconnect the PCV hose.

   Fig. 2: Remove the PCV hose and valve

5. Disconnect the vacuum hose and fuel return hose from the pressure regulator.
6. To disconnect the engine wiring harness, separate the harness from the intake manifold and delivery pipe. Disconnect the four injector harnesses. Make sure you label the wiring

   Fig. 3: Remove these four bolts for the engine wiring harness, along with two on the left side not shown

   Fig. 4: Remove the injector harness clips

   Fig. 5: Remove the harness from the injectors

7. Disconnect the fuel inlet pipe by removing the union bolt and two gaskets.

   Fig. 6: Place paper or cloth under the hose fittting before loosening

   Fig. 7: Remove the union bolt with gaskets to separate the fuel inlet pipe

   Fig. 8: The union bolt (1), washers (2) and fuel pipe (3)

8. Unbolt and remove the delivery pipe, injectors and two spacers.

   Fig. 9: Remove these two bolts to extract the delivery pipe . . .

   Fig. 10: . . . make sure the spacers are not lost during removal

   Fig. 11: The whole rail with injectors will come off the cylinder head

9. Remove the four insulators from the delivery pipe.
10. Remove the injector covers.

    Fig. 12: Remove these four bolts to pull off the injector covers

    Fig. 13: The covers are simply a small metal plate

    Fig. 14: Apply gasoline between the delivery pipe and injectors before removal

11. Remove the delivery pipe with injectors.
12. Remove the four gaskets at the end of the delivery pipe.

    Fig. 15: Remove the four grommets on each end of the delivery pipe where an injector is

13. Apply gasoline between the delivery pipe and injectors.
14. Place SST 09268–74010 or equivalent pin on the injector nozzle and push down on the delivery pipe to press out the injector.

    Fig. 16: Press the injector out of the delivery pipe

15. Remove the four injectors from the delivery pipe.
16. Remove the insulator and two O-rings from each injector.

    To install:

17. Apply a light coat of gasoline to two new O-rings.
18. Install the two O-rings and new insulator to each injector.

    Fig. 17: Apply a light coat of gasoline to O-rings and install them to the injector

19. By hand, push in the injector so that the injector connectors are in position.
20. Install the four insulators to the delivery pipe.
21. Install the two spacers, delivery pipe and two bolts. Tighten the bolts to 14 ft. lbs. (20 Nm).
22. Connect the fuel pipe with the gaskets and the union bolt and tighten the bolts to 20 ft. lbs. (29 Nm).
23. Attach the four injector connectors.
24. Secure the engine wire to the intake manifold and delivery pipe.
25. Connect the vacuum hose and fuel return hose to the pressure regulator.
26. Install the PCV hose.
27. Install the right hand engine service hole cover.
28. Connect the negative battery cable.
29. Start the engine and check for leaks.