Fuel Injection Disassembly and Repair

Fuel System
Section 5C - Fuel Injection Disassembly and Repair
Table of Contents
Disassembly...................................................................... 5C-2 Throttle Body Removal............................................... 5C-3
Flame Arrestor................................................................... 5C-2 Throttle Body Cleaning and Inspection.......................5C-5
Flame Arrestor Removal.............................................5C-2 Throttle Body Installation............................................ 5C-5
Flame Arrestor Cleaning and Inspection.................... 5C-3 Fuel Rail.............................................................................5C-8
Flame Arrestor Installation..........................................5C-3 Fuel Rail and Fuel Injector Components.................... 5C-8
Throttle Body..................................................................... 5C-3

5
C

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Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
66 Loctite 242 Threadlocker Threads of throttle body mounting studs 92-809821

Special Tools
Fuel Pressure Gauge Kit 91‑881833A03

Tests the fuel pump pressure; can be used to relieve fuel pressure.

2807

Digital Pressure Meter 91‑892651A01

Connects to the fuel system/manifold and can be used in conjunction with

Computer Diagnostic System (CDS).

5786

Disassembly
Flame Arrestor
Flame Arrestor Removal
1. Remove the retaining nut.
2. Remove the engine cover, if equipped.
3. Remove the flame arrestor retainer bracket.
4. Remove the breather hose.

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5. Remove the flame arrestor from the throttle body.

d
c

e
6110

a- Engine cover knob

b- Engine cover
c- Flame arrestor nuts
d- Cover mount bracket
e- Flame arrestor
f- Crankcase ventilation hose

Flame Arrestor Cleaning and Inspection

Clean the flame arrestor in steam or water.
Dry the flame arrestor with compressed air.

Flame Arrestor Installation

1. Install the flame arrestor on the throttle body.
2. Install the breather hose.
3. Install the flame arrestor retainer bracket.
4. Install the engine cover.
5. Install and tighten the retaining nut to the specified torque.

Description Nm lb‑in. lb‑ft

Flame arrestor retaining nut 12 106 –

Throttle Body
Throttle Body Removal
1. Remove the engine cover and the flame arrestor.

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Fuel Injection Disassembly and Repair
2. Disconnect the throttle linkage from the throttle body.

a - Nuts
b b - Throttle cable

29061
3. Disconnect the harness connectors from the throttle position sensor (TPS) and the idle air control (IAC) valve.

a c
b d 14 pin model
a - Throttle body
b - TPS
c - TPS harness connector
d - IAC

42540

10 pin model
a - TPS
b - IAC hose

b 29062

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 Fuel Injection Disassembly and Repair
4. Remove the throttle body attaching studs.

29064

Removing studs

5. Remove the throttle body.

6. Remove and discard the throttle body sealing ring.

a b a - Sealing ring
b - Throttle body

29065
IMPORTANT: Insert a clean shop towel into the opening of the intake manifold to prevent foreign material from entering
the engine.

Throttle Body Cleaning and Inspection

IMPORTANT: Do not use cleaners containing methyl ethyl ketone.
IMPORTANT: Do not contaminate the throttle position sensor (TPS) with cleaner or solvent.
IMPORTANT: Do not damage the adapter or throttle body when removing gasket material.
1. Carefully remove the gasket material from the intake manifold adapter and throttle body.
2. Remove the TPS.
3. Remove the IAC muffler.
4. Clean or replace the IAC muffler if grey or black. The muffler should be white. Refer to Section 5B ‑ MPI Fuel Delivery
Systems.
5. Thoroughly clean all parts of the throttle body. Ensure that all passages are free of debris and burrs.
6. Inspect the gasket mating surfaces for damage that could affect sealing.
7. Inspect the throttle body casting for cracks.
8. Inspect the throttle plates, linkage, return springs, and other components for damage, wear, and foreign material.

Throttle Body Installation

1. Install any components that were removed during the inspection and cleaning process.
2. Install a new throttle body sealing ring into the groove in the bottom throttle body plate.
3. Align the dowels and install the throttle body onto the upper intake manifold.
4. If reusing the fasteners, apply Loctite 242 Threadlocker to the threads of the throttle body mounting studs.

Tube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker Threads of throttle body mounting studs 92-809821

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Fuel Injection Disassembly and Repair
5. Install and tighten the throttle body mounting studs to the specified torque.

29064

Throttle body mounting studs

Description Nm lb‑in. lb‑ft

Throttle body mounting studs 9 80 –
6. Install the IAC muffler.
7. Install the throttle cable bracket. Tighten the nuts to the specified torque.

Description Nm lb‑in. lb‑ft

Throttle cable bracket nuts 19 168 –
8. Connect the harness connector to the TPS and attach the IAC hose to the throttle body IAC plug.

a c
b d 14 pin model
a - Throttle body
b - TPS
c - TPS harness connector
d - IAC

42540

10 pin model
a - TPS
b - IAC hose

b 29062

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 Fuel Injection Disassembly and Repair

9. Install the flame arrestor. Tighten the nut to the specified torque.

d
c

e
6110

a- Engine cover knob

b- Engine cover
c- Flame arrestor nuts
d- Cover mount bracket
e- Flame arrestor
f- Crankcase ventilation hose

Description Nm lb‑in. lb‑ft

Flame arrestor retaining bracket nut 12 106 –
10. Install the engine cover.

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Fuel Injection Disassembly and Repair

Fuel Rail
Fuel Rail and Fuel Injector Components
Removal
e
f
g
h i

d j

a b

52879
c

a- Fuel damper
b- O‑ring
c- O‑ring
d- Clip
e- Fuel rail
f- Dust cap
g- Fuel pressure service valve
h- Retainer
i- O‑ring
j- Fuel injector (6)
k- O‑ring

! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

1. Disconnect the negative (–) battery lead.

! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
2. Use a fuel pressure gauge to relieve pressure at the Schrader valve on the fuel rail. Drain the fuel into a suitable container
and dispose of the fuel in a safe manner.

Fuel Pressure Gauge Kit 91‑881833A03

Digital Pressure Meter 91‑892651A01
3. Remove the fuel feed line from the fuel rail.

Description SPX Part Number

Fuel line disconnect tool J‑44581
4. Use compressed air to remove dirt and debris from the fuel rail and injector area before removing the rail and injectors.

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5. Remove the relay bracket with relays.

6. Disconnect the injector connectors.
7. Remove the vacuum line from the fuel regulator.
8. Remove the breather tube from the manifold.
9. Remove the throttle body. Refer to Throttle Body Removal.

a - Screws retaining fuel rail

b - Breather tube
a

a
a

52931
10. Remove the four screws retaining the fuel rail to the manifold.
IMPORTANT: Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector
terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel
rail components.
11. Carefully raise the fuel rails. Lift evenly on both sides of the fuel rail until all injectors are removed from their bores.

Installation
1. Inspect the injector and fuel regulator O‑rings for damage. Replace if necessary.
NOTE: Lubricate the fuel injector O‑ring seals with clean engine oil.
2. Install the injectors into the fuel rails.
3. Install the fuel rail onto the intake manifold. Ensure that the fuel rail and injectors are seated evenly so that the O‑rings are
not damaged.
4. Install the four screws retaining the fuel rail to the manifold.

Description Nm lb‑in. lb‑ft

Fuel rail retaining screws 12 106 –
5. Install the throttle body with a new gasket. Refer to Throttle Body Installation.
6. Connect the vacuum line to the fuel regulator.
7. Connect the breather tube to the manifold.
8. Connect the fuel feed line to the fuel rail.
9. Connect the injector connectors.
10. Install the relay bracket with relays.
11. Install the flame arrestor and engine cover. Refer to Flame Arrestor Installation.
12. Connect the battery.
13. Pressurize the fuel system and inspect for leaks.

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Fuel Injection Disassembly and Repair

Notes:

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