Removing and Installing Injectors
The fuel injectors are removed and installed by removing the fuel rail. Although the entire assembly of fuel rail and injectors can be removed as a unit, it may be easier to first remove the fuel rail from the injectors and then remove the individual injectors from the engine.
To remove injector fuel rail and injectors:
| 1. | Disconnect the negative (-) battery terminal, and disconnect the main electrical connector at the fuel rail. |
| 2. | Remove the idle stabilizer valve. Disconnect the electrical connector, then remove the hoses and mounting bracket. See Fig. 4-37. |
| Fig. 4-37. | Exploded view of idle air stabilizer system showing mounting brackets and hose connections. |
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| 3. | Loosen the hose clamp and disconnect the crankcase ventilation hose from the throttle body. Swing the hose out of the way. |
| 4. | Remove the vacuum hose and the blue fuel return hose from the fuel pressure regulator. See Fig. 4-38. |
WARNING-
| Fig. 4-38. | Exploded view of Digifant II fuel rail and fuel injector mounting components. |
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Fuel will be expelled. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.
| 5. | Remove two Phillips-head screws and remove the pressure regulator. Using a 6-mm hex wrench, remove the socket-head mounting bolt and the pressure regulator mounting bracket. |
NOTE-
It may be easier to remove the rubber intake air boot to gain better access to the pressure regulator. To remove the boot, remove the clamps and pull the boot from the engine. Cover the openings with a clean, lint-free cloth.
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| 6. | Using a 5-mm hex wrench, remove the two socket-head fuel rail mounting bolts. Pry off the injector mounting clips using a small, flat-bladed screwdriver. |
| 7. | Remove the black fuel supply line from the connection atop the fuel rail. |
WARNING-
Fuel will be expelled. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.
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| 8. | Disconnect the injector connectors and pull the fuel rail from the injectors. |
NOTE-
If necessary, cut the wire ties which secure the wiring harness to the fuel rail, and disconnect the connectors after removing the fuel rail.
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| 9. | Remove each injector from its insert, and check the insert tightness. Remove any that are loose using a 10 mm hex wrench. |
Installation is reverse of removal. Replace injector or pressure regulator O-rings that are hard, cracked, or otherwise damaged. Clean the threads of the injector inserts, apply thread locking compound to the threads, and install and torque them to 20 Nm (15 ft. lb.). Be sure the injector's electrical connections are aligned correctly and that the injectors are fully seated prior to installing the fuel rail. Use new hose clamps.
Torque the fuel rail mounting bolts to 10 Nm (7 ft. lb.) and the pressure regulator mounting bolt to 15 Nm (11 ft. lb.). Mount the idle stabilizer valve and torque the mounting bolt to 10 Nm (7 ft. lb.). Reconnect the main electrical connector and the negative (-) battery terminal. Recheck the resistance of the injectors as described above in Testing Injectors.
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