Service Manual

3.15
ELECTRONIC FUEL INJECTION
3
Injector leakage is very unlikely, but in rare instances it can be
internal (past the tip of the valve needle), or external (weeping
around the injector body). The loss of system pressure from the
leakage can cause hot restart problems and longer cranking
times.
Injector problems due to dirt or clogging are unlikely due to the
design of the injectors, the high fuel pressure, the use of filters
and the detergent additives in the gasoline. Symptoms that could
be caused by dirty/clogged injectors include rough idle,
hesitation/stumble during acceleration, or triggering of fault
codes related to fuel delivery. Injector clogging is usually caused
by a buildup of deposits on the director plate, restricting the flow
of fuel, resulting in a poor spray pattern. Some contributing
factors to injector clogging include; dirty air filters, higher than
normal operating temperatures, short operating intervals and
dirty, incorrect, or poor quality fuel. Cleaning of clogged
injectors is not recommended; they should be replaced.
Additives and higher grades of fuel can be used as a preventative
measure if clogging has been a problem.
Fuel Injector Test
If an injector is not operating, it can indicate either a bad injector,
or a wiring/electrical connection problem. Check as follows:
• Remove the seat, left-hand side panel, and disconnect
the fuel injector(s).
• Using an ohmmeter, test for continuity by placing the
test leads on each pin of the injector.
• Resistance specification is 13.8Ω - 15.2Ω (20°C, 68°F)
Fuel Injector Replacement
NOTE: Engine must be cool. Depressurize the fuel
system if possible.
1. Remove the seat and both upper side panels (see Chapter 9
“Seat and Side Panels”).
2. Remove the (2) screws retaining the lower portion of the
air box.
3. Remove the hose from the breaker valve located on top of
the valve cover.
4. Remove the spark plug wires.
5. Remove the (2) Torx-head screws retaining the upper
portion of the air box to the front cab.
6. Carefully disconnect the ECU by pulling the tab out while
pulling down on the connector.
7. Loosen the hose clamp retaining the intake boot to the
intake plenum and remove the boot.
8. Lift up on the air box and turn it sideways to gain access to
the fuel rail and fuel injectors.
9. Thoroughly clean the area around the fuel rail and injectors.
10. Disconnect the “quick connect” fuel line from the fuel rail.
11. Disconnect the harness from both fuel injectors.
12. Using a 10 mm wrench, remove the fuel rail mounting
screws.
13. Carefully pull up on the fuel rail and fuel injectors and
remove them from the vehicle as an assembly.
14. Pry the two injector retaining tabs open and remove the
injector(s) from the fuel rail.
NOTE: Use new O-rings (included with new injector)
any time an injector is removed.
15. Lubricate the O-rings lightly with soapy water to aid
installation.
16. Install the new injector and torque the fuel rail mounting
screws to 6 - 9 ft. lbs. (8 - 12 Nm).
Fuel Injector Resistance Specification:
13.8Ω - 15.2Ω (20°C, 68°F)
Injectors
Fuel Rail