Section 08 ENGINE MANAGEMENT (4-TEC)
Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)
1
R1503motr163A
1. Fuel injector connectors
Disconnect fuel hose.
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R1503motr162B
1. Insert pointed tools each side
Wrap a rag around the hose end to prevent rail
draining.
Cut tie raps and remove the wiring harness from
the fuel rail.
Unscrew rail retaining screws.
Gently pull rail up by hand, working each side
slightly at a time.
Pull rail out with fuel injectors.
If necessary remove fuel injectors as described
below.
Installation
For installation, reverse the removal process but
pay attention to the following.
A thin film of injection oil should be applied to
O-rings of fuel injectors to ease installation in in-
take manifold.
Apply Loctite 243 on rail retaining screws then
torque to 10 N•m(89lbf•in).
When installing fuel line connector to the fuel rail,
put some oil on the O-ring to ease installation.
WARNING
Perform a fuel pressure test and ensure that
thereisnoleak. RefertoFUELPUMPabove.
Run engine and check for leaks.
FUEL INJECTOR
IMPORTANT: Never mix up fuel injectors of nat-
urally-aspirated and supercharged 4-TEC engines.
Doing so will automatically lead to a misfunction of
the EMS and will cause a bad engine calibration.
Leakage Test
To perform a leakage test, the injectors and fuel
rail have to be removed from the engine. Refer to
REMOVALinFUELRAILREPLACEMENTforthe
procedure.
NOTE: Do not detach injectors from the fuel rail.
Reconnect the fuel line and the wiring harness.
Place each injector in a clean bowl.
Install the safety lanyard cap on the DESS post to
activate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 drop per minute. Per-
form the test for 2 minutes.
If not within specification, replace the fuel injec-
tor(s).
Properly reinstall removed parts.
The leakage test is validated when performing the
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section.
Electrical Test
Voltage Test
SafetylanyardmustbeonDESSpost.
Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the fuel injector
from the Activation tab.
smr2004-Complete Line Up 415
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