Fuel Injector: Service and Repair

REMOVAL
1. Relieve fuel line pressure.

Fuel Pump Relay:

2. Remove negative battery cable.
3. Remove intake plenum.
4. Remove electrical connectors from fuel injectors and engine coolant temperature switch (ATX only).
5. Carefully bend wire harness retainer brackets away from harness and move harness assembly away from intake manifold.
6. Remove fuel supply line from pulsation damper.

Fuel Return Line:

7. Remove fuel return line bracket from intake manifold and remove clamp and return fuel line at bracket.

Fuel Supply Manifold:

8. Remove attaching bolts, spacers, insulators, and fuel rail with injectors, pressure regulator, and pulsation damper attached.
9. Remove fuel injectors, grommets, and O-rings from fuel rail.
10. Remove O-rings from injectors.

INSTALLATION
1. Position grommets and new O-rings onto injectors. Apply a small amount of engine oil to aid installation.
2. Position insulators and injectors into intake manifold.

Fuel Injector:

3. Position spacers and fuel rail on injectors.
4. Install spacers and attaching nuts to fuel rail and torque attaching bolts.
5. Install electrical connectors to injectors and coolant temperature switch (ATX only).
6. Install fuel return line brackets onto intake manifold and install return fuel line at bracket; secure the clamp.
7. Install fuel supply line onto pulsation damper and secure with clamp.
8. Install intake plenum.

Intake Manifold Components:

9. Install wiring harness into retainer brackets and carefully bend brackets toward wire harness.
10. Install negative battery cable.