Repair 7

Remove the cable from the negative battery terminal, using a socket wrench, to prevent the battery from generating sparks. Disconnect the air cleaner and its hose. Remove the upper and lower bonnets from the throttle body.

Press the tabs on the electrical wire for the fuel injector and pull the wire up to disconnect it from the fuel injector. Remove the screws from the retainer clip on the fuel injector, using a socket wrench, and detach the retainer clip from the fuel injector.

Grab the center collar of the fuel injector between the electrical terminals with a small pair of pliers. Rock the fuel injector gently back and forth while lifting it from the injector bore of the throttle body. Ensure that you do not twist the fuel injector while removing it. Discard all of the O-rings and the centering ring from the fuel injector.

Apply a coating of transmission fluid to the new O-rings and install them into the injector bore of the throttle body. Place the new centering ring on top of the upper O-ring. Align the fuel injectors locating ring, with its slot on the injector housing of the throttle body. Place the fuel injector into the injector bore of the throttle body and attach the retaining clip. Fasten the screws for the retainer clip, using a socket wrench.

Connect the electrical wiring for the fuel injector. Attach the upper and lower bonnets to the throttle body, using a socket wrench. Install the air cleaner and connect the air cleaner house. Attach the cable for the negative battery terminal.

Remove the cap on the fuel tank to relieve the pressure in the fuel tank. Attach fuel pressure gauge T80L-9974-A to the pressure relief valve on the fuel supply manifold. Open the pressure gauge to relieve the pressure in the fuel system.

Remove the upper intake manifold with a socket wrench. Disconnect the electrical wiring harness for the fuel injectors. Release the retaining clips for the fuel lines to the fuel supply manifold and disconnect the fuel lines.

Remove the retaining bolts for the fuel supply manifold and disconnect the fuel rail from the fuel injectors by lifting the fuel rail and gently rocking it back and forth. Disconnect the fuel injectors from the intake manifold in the same manner.

Remove the O-rings from the fuel injectors, and replace them if they show signs of damage. Lubricate the O-rings with engine oil and place them onto the new fuel injectors. Install the fuel rail and fuel injectors to the intake manifold. Ensure the O-rings are properly seated by pushing down on the fuel rail.

Tighten the retaining bolts for the fuel rail assembly to between 15 and 22 foot-pounds with a torque wrench. Attach the fuel lines to the fuel supply manifold and attach the electrical wiring harness for the fuel injector. Install the upper intake manifold with a socket wrench. Start the engine and check for fuel leaks.

Disconnect the cable from the negative battery terminal with a socket wrench. Wrap a shop towel around the banjo bolt on the fuel rail. Loosen the bolt slowly to relieve the pressure in the fuel rail. Tighten the banjo bolt.

Position a drain pan under the drain plug for the radiator. Remove the plug with a socket wrench and allow the coolant to drain into the pan. Replace the drain plug.

Disconnect the cables to the throttle and accelerator with a socket wrench. Detach the air intake duct. Remove the main wiring harness for the engine and move it out of the way. Disconnect any additional wires and hoses needed to access the fuel injectors in your vehicle.

Detach the electrical connectors from the fuel injectors. Release the clamps that attach the wiring harness to the fuel pipe, and remove the wiring harness. Remove the fuel rail and fuel injectors from the intake manifold as an assembly. Remove and discard the insulators and O-rings for the fuel injector.

Remove the hose from the bi-metal vacuum switching valve. Disconnect the bolts from the number two and number three fuel pipes with a socket wrench, and detach the fuel injectors from the fuel rail.

Insert a new insulator into the injector bore on the intake manifold. Place a new O-ring onto the nozzle end of the fuel injector, and coat the O-ring with a thin layer of gasoline. Press the fuel injector firmly to mount it squarely to the fuel rail.

Connect the fuel rail to the intake manifold, and tighten the mounting bolts to between 11 and 15 ft. lbs. with a torque wrench. Ensure the fuel injectors turn freely. Attach the the wiring harness to the fuel rail and plug the electrical connectors into the fuel injectors.

Connect any additional wires and hoses that you removed in step 3. Install the air intake duct and throttle body with a socket wrench. Fill the radiator with coolant and attach the cable to the negative battery terminal. Start the engine and check for fuel and coolant leaks.

Remove the fuel pump fuse from the fuse box under the dashboard. Start the engine, and allow it to idle until it stalls. This will relieve the pressure in the fuel system. Turn the engine off, and replace the fuel pump fuse in the fuse box.

Disconnect the negative battery cable with a socket wrench. Wrap a clean shop cloth around the fitting on the fuel line to the fuel rail. Remove the union nuts from the fuel line, and disconnect the fuel line from the fuel rail.

Remove the mounting bolts for the fuel rail with a socket wrench, and disconnect the fuel rail from the engine as an assembly. Turn the fuel injectors counterclockwise and remove them from the injector hole on the cylinder head. Remove and discard the heat shields from the injector hole.

Install new heat shields to the injector hole, and screw the new fuel injector into its hole. Tighten the fuel injector with a socket wrench, and install the fuel rail to the engine.

Connect the fuel line fuel rail, and fasten the union nuts for the fuel line with a socket wrench. Connect the negative battery cable.

Clean the fuel injector nozzles and the surrounding area with clean fuel oil to avoid contaminating the engine when you remove the fuel injectors. Clean the fuel line connections to the fuel injector to keep debris out of the fuel system. Blow the fuel injectors clean with an air compressor.

Release the clamps on the fuel lines to the fuel injectors, and disconnect the fuel lines from the fuel injectors. Remove the leak-off tees from the fuel injectors, and move them out of the way. Cover the open ends of the fuel injectors with plastic caps to keep dirt out of the fuel injectors.

Turn the fuel injectors counterclockwise with a socket wrench, and remove them from the injector bores. Cover the nozzle ends of the fuel injectors with plastic caps to avoid fuel contamination.

Extract the copper gasket from the injector bore with special tool T71P-19703-C, if the gasket is not on the fuel injector nozzle.

Store the fuel injectors in a holder with numbered holes. Place each fuel injector in the hole corresponding to that fuel injectors cylinder number. This ensures that you will reinstall each fuel injector into the correct injector bore.

Disconnect the air intake hose over the fuel rail with a socket wrench to access the fuel rail. Remove the plastic caps that cover the fuel rail.

Remove the pair of screws that attach the electrical plug plate to the fuel injectors with a 25mm socket. Unplug the electrical plate from the fuel injectors.

Disconnect the three mounting bolts on the fuel rail with a socket wrench and lift the fuel rail from the intake manifold. Detach the electrical plugs from the fuel injectors. Remove the retainers from the fuel injectors and disconnect the fuel injectors from the fuel rail.

Replace any damaged O-rings on the fuel injector and lubricate the O-rings with petroleum jelly. Install the fuel injectors to the fuel rail and plug the electrical connectors into the fuel injectors.

Mount the fuel rail to the intake manifold and torque the mounting bolts to between 6.5 and 8.0 ft. lbs. with a torque wrench. Connect the electrical plug plate to the fuel rail and fasten the pair of 5mm screws to the plug plate. Replace the cover and plastic plugs for the fuel rail. Connect the air intake hose.

Loosen the bleed bolt on the fuel rail with a socket wrench. Push the fuel primer on the fuel transfer pump until the fuel coming from the bleed valve no longer has air bubbles. Tighten the bleed bolt to 72 inch-pounds with a torque wrench.

Disconnect the negative battery cable by loosening the terminal nut with a socket wrench. This will prevent the accidental discharge of fuel as you remove the fuel injectors. Disconnect the valve cover with a socket wrench and detach the fuel lines from the fuel injectors.

Remove the retaining nut for the high-pressure fuel connector on each fuel injector. Disconnect the high-pressure connectors from the fuel injectors with tool 9015.

Disconnect the exhaust rocker arms with a socket wrench. Remove the retaining nuts from the solenoid wire, located on top of the fuel injectors. Disconnect the hold-down clamp bolts on the fuel injector. Remove the rocker-housing bolt with a socket wrench.

Connect the lower half of the mounting stud on tool 9010-2004 to the center of the bridge for the rocker housing. Connect the upper half of the mounting stud on tool 9010-2004 to the lower half of the mounting stud.

Connect the handle of tool 9010-2004 to the mounting stud on the tool. Tighten the nut on the tool to loosely connect the handle to the mounting stud. Connect the lower half of the clam shells on the special tool to the sides of the fuel injector. Connect the upper half of the clam shells to the head of the tool handle.

Slide the retaining sleeve over the pivoting handle of tool 9010-2004. Push the handle of the tool down to force the fuel injectors out of the cylinder heads. Remove the fuel injectors from the cylinder heads.

Disconnect the mounting bolts for the valve cover with a socket wrench and remove the valve cover. Detach the wiring harnesses from the fuel injectors.

Disconnect the oil rail drain plugs and fuel rail drain plugs with a socket wrench. Disconnect the oil deflector by removing its retaining screw.

Remove the mounting bolt on the outboard side of the fuel injector with a socket wrench. Disconnect the retaining hardware from the heater distribution box, including the screws, nuts and clips. Remove the heater distribution box.

Connect the injector remover no. T94T-9000-AH1 to the fuel injector plate with the injector removers screw. Tighten the screw to lift the fuel injector from the injector bore. Discard the copper washers for the fuel injector.

Clean the injector bore with the rotunda injector sleeve brush and a shop towel. Mount a new copper washer to the new fuel injector and coat the fuel injector with engine oil to lubricate it.

Place the fuel injectors into the injector bore and ensure that you properly seat the O-rings. Position the injector replacer No. T94T-9000-AH2 between the fuel injector and its hold-down plate. Tighten the bolt on the injector replacer to fully seat the fuel injector into the injector bore.

Perform steps one through three in reverse order to complete the fuel injector replacement. Torque the retaining screw on the oil deflector to 108 inch-pounds with a torque wrench. Torque the fuel rail drain plugs to 96 inch-pounds and torque the oil rail drain plugs to 53 inch-pounds.

Remove the fuse for the fuel pump from the fuse block under the dashboard. Start the engine and allow it to idle until it stalls. Crank the engine again to ensure the fuel system is empty. Turn the ignition off and replace the fuse for the fuel pump.

Disconnect the cable to the batterys negative terminal with a socket wrench. This will ensure you dont inadvertently crank the engine while installing the fuel injectors. Disconnect the air cleaner and detach the electrical connector for the fuel injector.

Remove the mounting screws and washers for the cover to the fuel meter with a socket wrench. Disconnect the cover for the fuel meter while leaving the gasket in place. Detach the fuel injector from the throttle body by gently prying it out with a small pry tool. Discard the large O-ring and washer from the top of the fuel injector cavity. Discard the small O-ring at the bottom of the injector cavity.

Lubricate the new small O-ring with transmission fluid. Install the small O-ring onto the fuel injectors nozzle, ensuring that the O-ring is flush against the fuel filter for the injector. Install the new washer into the fuel injector cavity. Lubricate the new, large O-ring. Press the large O-ring into the cavity against the washer so that the O-ring is flush with the surface of the fuel meter body.

Align the lug on the base of the fuel injector with the notch on the fuel meter body. Push and twist the fuel injector to install it into the cavity of the fuel meter body. Press down on the fuel injector to ensure that is completely seated within the cavity.

Replace the cover for the fuel meter and fasten the retaining screws with a socket wrench. Connect the electrical connector for the fuel injector and install the air cleaner. Connect the cable for the negative battery terminal.