GM Full Size Vans 1987-1997 Repair Guide

Fuel Injectors

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REMOVAL & INSTALLATION



See Figures 1 through 8


WARNING
When removing the injectors, be careful not to damage the electrical connector pins (on top of the injector), the injector fuel filter and the nozzle. The fuel injector is serviced as a complete assembly ONLY. The injector is an electrical component and should not be immersed in any kind of cleaner.



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Fig. Fig. 1: Fuel injectors and components

  1. Remove the engine cover and air cleaner. Relieve the fuel system pressure. Refer to the fuel relief procedure in this section.
  2.  
  3. At the injector connector(s), squeeze the two tabs together and pull straight up.
  4.  
  5. Remove the fuel meter cover and leave the cover gasket in place.
  6.  
  7. Using a small prybar or tool No. J-26868 or equivalent and a round fulcrum, carefully pry the injector until it is free from the fuel meter body.
  8.  
  9. Remove the small O-ring from the nozzle end of the injector. Carefully rotate the injector's fuel filter back and forth to remove it from the base of the injector.
  10.  
  11. Discard the fuel meter cover gasket.
  12.  
  13. Remove the large O-ring and back-up washer (if equipped) from the top of the counterbore of the fuel meter body injector cavity.
  14.  



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Fig. Fig. 2: Disengage the electrical connection



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Fig. Fig. 3: Unfasten the fuel meter cover retaining screws ...



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Fig. Fig. 4: ... then remove the fuel meter cover



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Fig. Fig. 5: Using a metal dowel as a fulcrum and a prytool to remove the injectors from their bores



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Fig. Fig. 6: Remove the injectors ...



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Fig. Fig. 7: ... then remove and discard the O-ring seals

To install:
  1. Lubricate the new lower O-rings with automatic transmission fluid and then push on the nozzle end of the injector until it presses against the injector fuel filter.
  2.  
  3. Position the injector back-up washer into the fuel meter bore.
  4.  
  5. Lubricate the new upper O-rings with automatic transmission fluid and then position it over the back-up washer so that it seats properly and is flush with the top of the meter body. Positioning must be correct or the injector will leak after installation.
  6.  
  7. Install the injector so that the raised lug on the injector base is aligned with the notch in the fuel meter body cavity. Press down on the injector until it is fully seated. The electrical terminals should be parallel with the throttle shaft.
  8.  
  9. Install the cover gasket and the meter cover.
  10.  
  11. Reconnect the electrical leads, start the engine and check for leaks.
  12.  



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Fig. Fig. 8: Installing the TBI injector

 
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