DO NOT: Tap on fuel injectors to correct any
malfunction.
Can damage injector.
DO NOT: Replace the injector with other
part number not recommended for this
application
Will severely affect the performance of the
injector
DO: Take extra care when installing new
fuel seal ring over injector inlet flange.
Prevent tearing seal ring during installation.
DO: Use proper lubricants on seal ring
surfaces to install injector in engine.
Minimize time between applying lubricant
and inserting injector / rail.
Avoid damage to seal ring during installation.
Avoid contamination at seal.
DO: Pulse (actuate) stuck closed or tip-leak
suspected injector (Actuate consists of one
pulse <5 sec duration at 9 to 15V).
To verify the injector failure
DO: Pulse (actuate) injectors prior to a dry
fuel system leak test at engine/vehicle
assembly to reseat injector valves.
Injector valves may not reseat without fuel
after shipping and handling resulting in false
leakage.
DO: Avoid any liquid contamination in the
injector area.
Coil could short circuit.
DO: Use care during connection of
harness to injector.
Avoid terminal damage.
DO: Use recommended terminal lubricant
on mating connector.
Minimize potential for terminal fretting
corrosion.
DO: Return any dropped, damaged, or
suspect material with a tag that describes
the problem.
Ensure fast and correct diagnosis of root
cause.
3. Installation guidelines
Follow these guidelines to prevent damage to the injector and its electrical interface during the
replacement or re-installation process.
Lubrication: Apply a light coating of lubricant to the lower injector seal ring. ISO 10 light
mineral oil or equivalent is recommended.
The preferred technique is to apply the lubricant to the sockets the injectors are being
installed into, rather than directly to the seal ring itself. This will help minimize the
possibility of injector contamination.
Avoid applying lubricant over the director plate holes – this may restrict injector flow. Do
not dip the injector tip in lubricant.
Multec 3.5 injectors come from the factory with the seal rings attached. The re-use of seal
rings is not preferred when replacing an injector. If an injector is to be re-used, and no new
seal rings are available, take care to inspect each seal ring for signs of damage. Even
minor defects in the seal ring can lead to leakage. Take extra care in installing seal ring
over flange of injector inlet.
ENGINE MANAGEMENT SYSTEM
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Carefully installing the harness connector will prevent terminal damage. Listen for a
positive audible click from the connector retention device — this ensures that it is fully
engaged. Shut off ignition.
Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt
is made to start the engine.
Disconnect the electrical connector from the injector wiring harness.
Relieve fuel pressure
Remove the retaining clip from the fuel injector.
Remove the fuel line connection from the injector
Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces.
Remove the injector from the manifold
Apply a light coating of a lubricant to both the upper and lower injector seal ring of the
replacement injector.
Install the new injector into the manifold. Check that the injector is installed in the original
orientation to maintain proper spray targeting, and that the retaining clip is properly seated
on the injector and the fuel line
Install the retaining clip after connecting the fuel line
Tighten the injector mounting to the desired torque as mentioned in the manufacturer
manual
Tighten the fuel line
Re-install the injector electrical connector
Check for fuel leaks with the key “on” and the engine “off”
Start engine and verify proper operation.
or spray pattern, do not rotate the injector in the fuel rail assembly to install the injector
electrical connector. This may dislodge the retaining clip, and result in improper spray
orientation
4．Replacement Techniques
WARNING:
The injector and all associated hardware may be extremely hot.
Shut off ignition.
Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt
is made to start the engine.
Disconnect the electrical connector from the injector wiring harness.
Relieve fuel pressure
Remove the retaining clip from the fuel injector.
Remove the fuel line connection from the injector
Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces.
Remove the injector from the manifold
Apply a light coating of a lubricant to both the upper and lower injector seal ring of the
replacement injector.
Install the new injector into the manifold. Check that the injector is installed in the original
orientation to maintain proper spray targeting, and that the retaining clip is properly seated
on the injector and the fuel line
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