Repair 7

Chrysler manufactures a number of off-road vehicles under its Jeep marque, with the Wrangler being the most popular of these models. The 1989 Jeep Wrangler represents the first generation of the Jeep Wrangler, which was produced from 1987 to 1996. These vehicles were available with several different engines, all of which used fuel injection. The fuel injectors in a 1989 Jeep deliver fuel and air to the engine and are located on top of the engine.

Instructions

1

Disconnect the negative battery cable with the socket wrench. This will prevent the battery from producing sparks while you replace the fuel injector. Remove the air cleaner and its hose from the vehicle as an assembly. Remove the bonnets from the throttle body with a socket wrench.

2

Press the tabs on the wire for the fuel injector while pulling the wire up to detach it from the fuel injector. Disconnect the screws for the retainer clip on the fuel injector with a socket wrench. Remove the retainer clip from the fuel injector.

3

Grab the center collar of the fuel injector with a pair of small pliers. Remove the fuel injector by lifting and rocking the collar gently with the pliers without twisting the fuel injector. Discard both O-rings and the centering ring for the fuel injector.

4

Lubricate the new O-rings for the fuel injector with transmission fluid. Install them into the bore of the fuel injector and place the new centering ring on top of the upper O-ring. Install the fuel injector and attach the retaining clip. Fasten the screws for the retainer clip with a socket wrench.

5

Attach the electrical connector for the fuel injector and install the bonnets with a socket wrench. Install the air cleaner assembly and connect the cable for the batterys negative terminal.

The General Motors 3800 engine is a 3.8-liter V-6. This engine is installed across a variety of GM vehicles, though is primarily found in the Pontiac and Buick vehicle lines. The 3800 engines fuel injectors operate in conjunction with a pressurized fuel system. At the top and bottom of each injector, an o-ring acts as a seal to ensure fuel does not leak. Damaged or degraded o-rings may cause fuel leaks and fire hazards. O-ring replacement is recommended if they are leaking or any time the injector is removed from the fuel rail or engine.

Instructions

Remove the Injectors

1

Remove the electronic plug from the fuel safety cut-off switch to turn off the fuel pump. The cut-off switch location can be found in your vehicles owners manual.

2

Depressurize the fuel system by attempting to start the car three times, for 3 to 5 seconds each time. Allow a 10-second pause between attempts to allow the starter to cool. Without re-pressurization from the fuel pump, the existing pressure in the fuel lines will be reduced due to fuel consumption by the engine.

3

Disconnect the negative battery terminal.

4

Locate the fuel rails and remove any engine shrouds, intake tubes, vacuum lines or bolt-on accessories to allow access. Unbolt the fuel rail from the engine if your vehicles rails are secured.

5

Disconnect the fuel injector electronics plug. Disconnect the fuel rails by pulling upward and away from the top of the fuel injector. Some fuel will spill. Allow it to evaporate, or wipe it away, before continuing.

6

Pull upward on the fuel injector to remove from the engine. The fuel injector may need to be rocked slightly to allow the bottom o-ring to disengage.

Install the O-rings

7

Remove the o-rings from the injectors by sliding them off the top and bottom of the injector.

8

Wipe away any dirt or debris from the injector o-ring seal point.

9

Lubricate the new o-ring with a light coating of motor oil. The motor oil will not only make it easier to slide on, it will protect the o-ring once installed. Apply a small amount of motor oil to your finger and wipe over the entire surface of each o-ring.

10

Slide the o-rings onto the fuel injector.

Replace the Injectors

11

Push the injector into the engine hole until the o-ring is fully seated. A properly seated injector will resist removal.

12

Push the fuel rail or fuel line directly down on top of the fuel injector. Misaligned pressure may cause small tears in the injector creating future leak points. Connect all fuel injectors.

13

Replace the electronics plug on each fuel injector. Secure the fuel rail to the engine, if required. Attach any bolt-on accessories, vacuum hoses, and intake tubes. Reconnect the fuel safety shut-off switch electronics plug. Reconnect the car battery.

14

Turn the ignition switch to the electronics mode. Allow the fuel pump to pressurize the fuel system. With the ignition switch in the electronics mode, the pressurization should take 3 to 5 seconds. Turn off the key and repeat this step twice.

15

Inspect the fuel system for leaks. Return to Section 1, if necessary. Replace the engine shroud. Start the vehicle to confirm installation.

General Motors made an eight-cylinder 6.2 L diesel engine from 1982 until 1993. It was an optional engine that was most common on larger pickup trucks. The fuel injectors for this engine are on top of the engine, and each injector sends fuel to a cylinder in a specific sequence. The majority of the work of installing a fuel injector in a 6.2 L engine is removing the fuel lines so you can remove the old fuel injector.

Instructions

1

Disconnect the negative battery cable with a socket wrench to prevent anyone from starting the engine during the procedure. Remove the clip on the fuel return line, and detach the fuel return line from the fuel injectors.

2

Remove the air cleaner bracket from the valve cover with a socket wrench. Disconnect the crankcase ventilator bracket. Detach the fuel lines from the secondary fuel filter adapter and disconnect the secondary filter adapter. Release the clamp on the vacuum pump and move the pump aside to access the bolts for the intake manifold. Disconnect the intake manifold bolts and remove the intake manifold from the engine.

3

Cover the engine with GM part no. J-29664-1 to protect the open engine from debris. Disconnect the clips on the fuel injector lines from the loom brackets. Remove the fuel injector lines from the injector nozzles and place caps over the nozzles.

4

Detach the injector lines from the injector pump. Plug the open ends of the fuel lines with clean cloth to prevent contamination of the fuel lines.

5

Remove the fuel injector from the engine by turning the 30 mm hex portion of the fuel injector counterclockwise with GM special tool J-29873. Discard the gasket for the fuel injector.

6

Install a new fuel injector and gasket by turning the 30 mm hex portion of the injector clockwise with GM special tool J-29873. Tighten the injector to 50 foot-pounds with the special tool and a torque wrench.

7

Remove the cloth from the ends of the fuel lines and connect the fuel lines to the injectors. Tighten the retaining nut for the fuel line to 20 foot-pounds with a torque wrench. Complete the installation of the fuel injector by performing Steps 1 through 3 in reverse sequence.

Mobil produces a series of fuel injector cleaner products that should be used in your vehicle to rid it of gas buildups. As you fill up, gasoline leaves deposits that have the potential to clog your fuel injectors, which slows the flow of gas throughout your vehicle. Using a fuel injector kit can remedy this. These small bottle kits come packed with detergents that break down the deposits that the gasoline creates, while freeing up the flow of gasoline.

Instructions

1

Crack open the fuel injector cleaner bottle. Throw away the cap and pull out the pouring tube until its at full length.

2

Remove the gasoline cap guarding the gas tank by twisting it hard to the left and pulling it all the way once its loose.

3

Push the pouring tube into the gas tank as if you were pumping gas.

4

Allow the entire bottle kit to pour into your gas tank and circulate.

5

Discard the bottle and close your gasoline tank.

Many vehicles made by General Motors from 1992 to 2000 have a 6.5-liter engine with eight cylinders. These engines were most common in larger trucks like 3/4-ton and larger pickup trucks. The General Motors 6.5-liter engine uses fuel injection and almost always had a turbocharger. This requires a fuel injector pump to transfer the fuel from the fuel tank to the engine under high pressure.

Instructions

1

Disconnect the cable from the negative battery terminal with a socket wrench. Wrap a fuel fitting in a heavy shop towel and loosen the fitting to relieve the pressure in the fuel system. Tighten the fuel fitting.

2

Remove the intake-manifold with a socket wrench. Disconnect the fuel lines and the electrical wiring from the injection pump. Detach the fuel return line from the top of the injection pump. Plug the open fuel lines with clean cloth to keep debris out of the fuel system. Remove the oil filler and its grommet from the engine.

3

Turn the crankshaft clockwise by hand until the gear bolts for the injection pump are visible through the hole for the oil filler neck. Remove the gear bolts with a socket wrench and disconnect the nuts that attach the injection pump to its front cover. Remove the injection pump from the engine.

4

Align the pin on the hub of the new injection pump with the slot in the gear for the injection pump. Turn the crankshaft clockwise to align the timing marks on the torsional damper with the zero mark on the timing tab. Connect the fuel injection pump to its front cover with a socket wrench. Tighten the nuts for the front cover to 30 foot-pounds of torque with a torque wrench.

5

Fasten the bolts that attach the injection pump to its driven gear and tighten them to 20 foot-pounds of torque with a torque wrench. Install the oil fill tube and its grommet. Connect the bracket for the air conditioner with a socket wrench. Remove the plugs from the fuel lines, and connect the fuel feed line to the injector pump. Tighten the retaining bolts for the fuel line to 20 foot-pounds of torque with a torque wrench.

6

Connect the fuel return line and electrical wiring to the injector pump. Replace the intake-manifold with a socket wrench and attach the cable for the negative battery terminal. Start the engine and correct any fuel leaks.