How To: Injector Swap for 98+

orangedime · 10-01-2008, 02:47 PM

I searched and searched and found a few different answers on how to change the injectors on a 98+ 2.2 so I decided to do a write up on it.

The only tools you will need are:

10mm socket
13mm socket
Random Socket Extensions
Flat Head Screwdriver
Door Panel Clip Tool
Fuel Line Quick Release Tool
Vaseline

I started by running the truck without the fuel pump relay in it until it shut off. This will release most of the pressure from the fuel system. You can release it with a shrader valve that is located at the rear of the fuel rail. Next step DISCONNECT THE BATTERY. Just in case.

Then I took the intake assembly off starting at the throttle body loosening all 4 of the hose clamps down to the air filter (don't forget the one under the upper radiator hose on the left side). At this point you can take the 10mm bolt and PVC hose off the upper intake box and pull it out. After that is out of the way you can use the clip release tool to remove the 3 clips holding the intake hose to the fan shroud and pull this bazooka looking hose out of the way. This is what the clip tool looks like.

You can now pull the fan shroud by removing 6 10mm bolts, 3 on the core support and 2 down on each side

At this point it should look like this:

Now it's time to deal with the fuel system. I started with releasing the flexible fuel line from the hard line that goes to the fuel rail. Start with taking the clip off the connection and unbolting the bracket that holds the line to the intake manifold. Then to make things easier I bought a quick connect release tool at Autozone for 6.95 and it only took a second to jam it into the connection and pull to release it.

Now the tricky part. You have to get the fuel rail disconnected, so start by disconnecting the wiring harness at the fuel rail right on top of the valve cover towards the rear. Then you have to release the 2 10mm bolts holding the rail to the intake manifold. They are really hard to get to but having the right tools and taking your time helps, I used a bunch of different extensions and swivel joints to get them out. Here are pics of where the bolts are after I got the fuel rail out.

This is the rear one between cylinder3 and 4 and the front one is between 1 and 2. They are kind of hard to see but they are the bronze looking bolt holes.

There is a Metal plate on the rear of the valve cover that you have to take off also, it has 2 13mm bolts that go into the valve cover and a 10mm bolt on the back of the valve cover towards the firewall. Do not take the 10mm bolt out all the way because the bracket just slides onto it and you only need to loosen it to take the bracket off.

This is the bracket.

Once the fuel rail is unbolted you can carefully pull on the fuel rail until you hear the injectors pop out. You are ready to slide it right out the front of the intake, but you have to be really careful not to snag the injectors on anything because you don't want to damage them unless you are replacing them, but even then you have to be careful putting them in.

Once it's out you can release each injector by unplugging the wire to each one. It comes off by pulling up on the blue clip until it hits the black tab and pushing on the tab to release it.

Then you release the clip holding the injector to the fuel rail with a screwdriver, be careful because it goes flying when you release it, so make sure it is pointed away from you when you pop it off.

Installation is the same as removal except I put a little vaseline on the injector seals and the intake hose that goes under the upper radiator hose to make everything slide together a little easier.

This is the lower intake hose I was talking about putting vaseline on. Do not use too much because you don't want any residual in your intake or injectors.

Good luck with it, and feel free to add any other info that will help people in doing this. You are liable for the work that you do so be careful and take your time.

ohio420jb · 10-01-2008, 04:45 PM

I don't have a need for this but thanks for taking the time to do this write up. I'm sure some one will find it very useful

Chris0nllyn · 10-01-2008, 05:04 PM

nice write up....way different for 94-97 though lol

rrray88sdime · 10-01-2008, 05:11 PM

def good write up. sticky!

ProTouring2.2 · 10-01-2008, 07:25 PM

what injectors did you swap for? or did you just replace them with stock

lee-mill · 10-01-2008, 07:35 PM

orangedime · 10-01-2008, 08:25 PM

Quote: Originally Posted by ProTouring2.2

what injectors did you swap for? or did you just replace them with stock

I am chasing a misfire. I decided to swap the injectors from cylinder 3 to cylinder 4 to see if the misfire moves with the injector before I went and bought a new one.

2002dime · 10-01-2008, 08:58 PM

http://cgi.ebay.com/ebaymotors/A-C-F...spagenameZWDVW

These make removing fuel lines easy. Nice write-up btw

orangedime · 10-01-2008, 09:30 PM

Quote: Originally Posted by 2002dime

http://cgi.ebay.com/ebaymotors/A-C-F...spagenameZWDVW

These make removing fuel lines easy. Nice write-up btw

Thanks. I got the cheapo one from autozone, but that is a good set if you work on a lot of cars.

Also thanks to whoever corrected the name of the thread.

This is a better pic of the one I used:

scottymizt · 10-01-2008, 09:31 PM

very nice write up i will be using ur words very soon please sticky this !!!!

Chris0nllyn · 10-02-2008, 12:06 AM

lol, ive got like 4 of those tools in my garage...now i know wat they're for

blazerxtreme18 · 10-02-2008, 12:09 AM

great writeup...i think theres a couple floating around here for the 4.3 too

Garage Customs · 10-02-2008, 12:23 AM

nice!

***What?*** · 10-02-2008, 01:38 AM

Took care of name and already listed in sticky

orangedime · 10-02-2008, 02:03 AM

Quote: Originally Posted by What?

Took care of name and already listed in sticky

Thank you

orangedime · 10-02-2008, 08:30 PM

Quote: Originally Posted by orangedime

I am chasing a misfire. I decided to swap the injectors from cylinder 3 to cylinder 4 to see if the misfire moves with the injector before I went and bought a new one.

Well, I reset the computer and drove it until the check engine light turned back on. The misfire moved with the injector, time to buy a new one and do it all over again.

S10dude · 10-02-2008, 09:08 PM

very nice write-up...good job!

tg900 · 10-03-2008, 12:10 AM

I'd suggest using new o-rings, they are like $10 for all eight. Just be sure you dont mix them up since they are different for upper and lower.

I'm a fan of doing jobs once. I had to replace my injectors at 210K miles, i think the original o-rings had enough.

orangedime · 10-03-2008, 02:05 AM

Quote: Originally Posted by tg900

I'd suggest using new o-rings, they are like $10 for all eight. Just be sure you dont mix them up since they are different for upper and lower.

I'm a fan of doing jobs once. I had to replace my injectors at 210K miles, i think the original o-rings had enough.

Good call. I inspected mine and they were perfect after only 45k, but if yours show any visible wear. Replace them.

beandip · 10-03-2008, 09:52 AM

Great writeup. I always thought you had to take the intake manifold off to get to those injectors.

rican 25 · 10-04-2008, 03:07 PM

man this is a blessing because I thought you had to take the intake off as well!! and... I am possibly getting ready to do the same thing as I am having a misfire and my computer has said that its in injector #4, already have the injector.. but I better go get those fuel line removal tools that I will probably never use again! lol
Thanks orangedime

orangedime · 10-04-2008, 08:30 PM

Quote: Originally Posted by rican 25

man this is a blessing because I thought you had to take the intake off as well!! and... I am possibly getting ready to do the same thing as I am having a misfire and my computer has said that its in injector #4, already have the injector.. but I better go get those fuel line removal tools that I will probably never use again! lol
Thanks orangedime

I also believed that you needed to take the intake manifold off to do the swap. But when I looked at it, I thought "why wouldn't it just slide out the front if I move everything out of the way?". I'm glad I tried it, hope this helps you through the process. Don't buy the injector until you swap them and confirm that it is the injector, no reason to spend $80 on a part if it's not going to fix the problem.

tg900 · 10-04-2008, 11:01 PM

meh i took my intake manifold off because i was hoping to do a cavi intake setup at the time..but the a/c blower box got in the way so all i did is change injectors and not intake.

duaneb9729 · 10-05-2008, 12:27 PM

does the fuel pressure regulator fit thru the intake manifold?

or do you have to remove it?

how does it come off? i removed the torx screw but i didnt have any luck getting it off the rail but i was reluctant to pull to hard or pry.

orangedime · 10-06-2008, 05:32 PM

Quote: Originally Posted by duaneb9729

does the fuel pressure regulator fit thru the intake manifold?

or do you have to remove it?

how does it come off? i removed the torx screw but i didnt have any luck getting it off the rail but i was reluctant to pull to hard or pry.

I didn't have a regulator on mine, maybe you can include a picture and someone can help you out.

This is a picture of what I pulled out as a full assembly

tg900 · 10-07-2008, 04:12 PM

The flex fuel models dont have a regualtor on the fuel rail...its in the fuel fuel sensor located right near the coilpacks

If you really need a picture I can take some this weekend...I got all kinds of fuel rails at home

fossunit43 · 08-18-2009, 06:30 PM

To bring this thread back to life, i would like some info on that fuel pressure regulator and how to get it off.

Thanks

dirty_drew · 08-20-2009, 12:25 AM

I ended up using a light dab of motor oil to lube it up instead of vaseline.

Nitestoker · 08-20-2009, 11:21 PM

Nice info, I will be performing surgery soon.

10-01-2008, 02:47 PM	#1
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	How To: Injector Swap for 98+ I searched and searched and found a few different answers on how to change the injectors on a 98+ 2.2 so I decided to do a write up on it. The only tools you will need are: 10mm socket 13mm socket Random Socket Extensions Flat Head Screwdriver Door Panel Clip Tool Fuel Line Quick Release Tool Vaseline I started by running the truck without the fuel pump relay in it until it shut off. This will release most of the pressure from the fuel system. You can release it with a shrader valve that is located at the rear of the fuel rail. Next step DISCONNECT THE BATTERY. Just in case. Then I took the intake assembly off starting at the throttle body loosening all 4 of the hose clamps down to the air filter (don't forget the one under the upper radiator hose on the left side). At this point you can take the 10mm bolt and PVC hose off the upper intake box and pull it out. After that is out of the way you can use the clip release tool to remove the 3 clips holding the intake hose to the fan shroud and pull this bazooka looking hose out of the way. This is what the clip tool looks like. You can now pull the fan shroud by removing 6 10mm bolts, 3 on the core support and 2 down on each side At this point it should look like this: Now it's time to deal with the fuel system. I started with releasing the flexible fuel line from the hard line that goes to the fuel rail. Start with taking the clip off the connection and unbolting the bracket that holds the line to the intake manifold. Then to make things easier I bought a quick connect release tool at Autozone for 6.95 and it only took a second to jam it into the connection and pull to release it. Now the tricky part. You have to get the fuel rail disconnected, so start by disconnecting the wiring harness at the fuel rail right on top of the valve cover towards the rear. Then you have to release the 2 10mm bolts holding the rail to the intake manifold. They are really hard to get to but having the right tools and taking your time helps, I used a bunch of different extensions and swivel joints to get them out. Here are pics of where the bolts are after I got the fuel rail out. This is the rear one between cylinder3 and 4 and the front one is between 1 and 2. They are kind of hard to see but they are the bronze looking bolt holes. There is a Metal plate on the rear of the valve cover that you have to take off also, it has 2 13mm bolts that go into the valve cover and a 10mm bolt on the back of the valve cover towards the firewall. Do not take the 10mm bolt out all the way because the bracket just slides onto it and you only need to loosen it to take the bracket off. This is the bracket. Once the fuel rail is unbolted you can carefully pull on the fuel rail until you hear the injectors pop out. You are ready to slide it right out the front of the intake, but you have to be really careful not to snag the injectors on anything because you don't want to damage them unless you are replacing them, but even then you have to be careful putting them in. Once it's out you can release each injector by unplugging the wire to each one. It comes off by pulling up on the blue clip until it hits the black tab and pushing on the tab to release it. Then you release the clip holding the injector to the fuel rail with a screwdriver, be careful because it goes flying when you release it, so make sure it is pointed away from you when you pop it off. Installation is the same as removal except I put a little vaseline on the injector seals and the intake hose that goes under the upper radiator hose to make everything slide together a little easier. This is the lower intake hose I was talking about putting vaseline on. Do not use too much because you don't want any residual in your intake or injectors. Good luck with it, and feel free to add any other info that will help people in doing this. You are liable for the work that you do so be careful and take your time.
	[Reply w/Quote]

10-01-2008, 04:45 PM	#2
ohio420jb Registered User Age: 28 Join Date: Jun 2004 Posts: 609 Location: SE Ohio User is: OffLine	re: How To: Injector Swap for 98+ I don't have a need for this but thanks for taking the time to do this write up. I'm sure some one will find it very useful
	[Reply w/Quote]

10-01-2008, 05:04 PM	#3
Chris0nllyn tu-tu guru Age: 22 Join Date: Jan 2004 Posts: 8,714 Location: Southern MD User is: OffLine	re: How To: Injector Swap for 98+ nice write up....way different for 94-97 though lol
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10-01-2008, 05:11 PM	#4
rrray88sdime ohhhh yeahhhhh Age: 21 Join Date: Jan 2006 Posts: 913 Location: Charlotte(Pineville) NC User is: OffLine	re: How To: Injector Swap for 98+ def good write up. sticky!
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10-01-2008, 07:25 PM	#5
ProTouring2.2 Have a nice day! Age: 21 Join Date: May 2005 Posts: 9,778 Location: NJ User is: OffLine	re: How To: Injector Swap for 98+ what injectors did you swap for? or did you just replace them with stock
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10-01-2008, 07:35 PM	#6
lee-mill where's my chippy? Age: 20 Join Date: Jun 2007 Posts: 7,832 Location: staatsburg, ny User is: OffLine	re: How To: Injector Swap for 98+
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10-01-2008, 08:25 PM	#7
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	re: How To: Injector Swap for 98+ Quote: Originally Posted by ProTouring2.2 what injectors did you swap for? or did you just replace them with stock I am chasing a misfire. I decided to swap the injectors from cylinder 3 to cylinder 4 to see if the misfire moves with the injector before I went and bought a new one.
	[Reply w/Quote]

10-01-2008, 08:58 PM	#8
2002dime Registered User Age: 27 Join Date: Jan 2008 Posts: 315 Location: Joplin, MO User is: OffLine	Re: How To: Injector Swap for 98+ http://cgi.ebay.com/ebaymotors/A-C-F...spagenameZWDVW These make removing fuel lines easy. Nice write-up btw
	[Reply w/Quote]

10-01-2008, 09:30 PM	#9
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	Re: How To: Injector Swap for 98+ Quote: Originally Posted by 2002dime http://cgi.ebay.com/ebaymotors/A-C-F...spagenameZWDVW These make removing fuel lines easy. Nice write-up btw Thanks. I got the cheapo one from autozone, but that is a good set if you work on a lot of cars. Also thanks to whoever corrected the name of the thread. This is a better pic of the one I used: Last edited by orangedime : 10-01-2008 at 09:35 PM.
	[Reply w/Quote]

10-01-2008, 09:31 PM	#10
scottymizt rb25det inside :D Join Date: Nov 2007 Posts: 341 Location: User is: OffLine	Re: How To: Injector Swap for 98+ very nice write up i will be using ur words very soon please sticky this !!!!
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10-02-2008, 12:06 AM	#11
Chris0nllyn tu-tu guru Age: 22 Join Date: Jan 2004 Posts: 8,714 Location: Southern MD User is: OffLine	Re: How To: Injector Swap for 98+ lol, ive got like 4 of those tools in my garage...now i know wat they're for
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10-02-2008, 12:09 AM	#12
blazerxtreme18 Registered User Age: 24 Join Date: Jun 2006 Posts: 1,697 Location: good ol'north jerz User is: OffLine	Re: How To: Injector Swap for 98+ great writeup...i think theres a couple floating around here for the 4.3 too
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10-02-2008, 12:23 AM	#13
Garage Customs Kurrupted Kreations Age: 24 Join Date: Jan 2006 Posts: 3,284 Location: Tulare, Ca User is: OffLine	Re: How To: Injector Swap for 98+ nice!
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10-02-2008, 01:38 AM	#14
*What?* Moderator Join Date: Jan 2004 Posts: 17,076 Location: AZ User is: OffLine	Re: How To: Injector Swap for 98+ Took care of name and already listed in sticky
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10-02-2008, 02:03 AM	#15
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	Re: How To: Injector Swap for 98+ Quote: Originally Posted by What? Took care of name and already listed in sticky Thank you
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10-02-2008, 08:30 PM	#16
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	Re: How To: Injector Swap for 98+ Quote: Originally Posted by orangedime I am chasing a misfire. I decided to swap the injectors from cylinder 3 to cylinder 4 to see if the misfire moves with the injector before I went and bought a new one. Well, I reset the computer and drove it until the check engine light turned back on. The misfire moved with the injector, time to buy a new one and do it all over again.
	[Reply w/Quote]

10-02-2008, 09:08 PM	#17
S10dude Marc Join Date: May 2006 Posts: 10,564 Location: Sacramento,Ca. User is: OffLine	Re: How To: Injector Swap for 98+ very nice write-up...good job!
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10-03-2008, 12:10 AM	#18
tg900 Dialed! Age: 22 Join Date: May 2006 Posts: 723 Location: PA User is: OffLine	Re: How To: Injector Swap for 98+ I'd suggest using new o-rings, they are like $10 for all eight. Just be sure you dont mix them up since they are different for upper and lower. I'm a fan of doing jobs once. I had to replace my injectors at 210K miles, i think the original o-rings had enough.
	[Reply w/Quote]

10-03-2008, 02:05 AM	#19
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	Re: How To: Injector Swap for 98+ Quote: Originally Posted by tg900 I'd suggest using new o-rings, they are like $10 for all eight. Just be sure you dont mix them up since they are different for upper and lower. I'm a fan of doing jobs once. I had to replace my injectors at 210K miles, i think the original o-rings had enough. Good call. I inspected mine and they were perfect after only 45k, but if yours show any visible wear. Replace them.
	[Reply w/Quote]

10-03-2008, 09:52 AM	#20
beandip I'm Back!! Age: 21 Join Date: Sep 2006 Posts: 6,954 Location: Somewhere, OK User is: OffLine	Re: How To: Injector Swap for 98+ Great writeup. I always thought you had to take the intake manifold off to get to those injectors.
	[Reply w/Quote]

10-04-2008, 03:07 PM	#21
rican 25 Registered User Join Date: Mar 2008 Posts: 317 Location: User is: OffLine	Re: How To: Injector Swap for 98+ man this is a blessing because I thought you had to take the intake off as well!! and... I am possibly getting ready to do the same thing as I am having a misfire and my computer has said that its in injector #4, already have the injector.. but I better go get those fuel line removal tools that I will probably never use again! lol Thanks orangedime
	[Reply w/Quote]

10-04-2008, 08:30 PM	#22
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	Re: How To: Injector Swap for 98+ Quote: Originally Posted by rican 25 man this is a blessing because I thought you had to take the intake off as well!! and... I am possibly getting ready to do the same thing as I am having a misfire and my computer has said that its in injector #4, already have the injector.. but I better go get those fuel line removal tools that I will probably never use again! lol Thanks orangedime I also believed that you needed to take the intake manifold off to do the swap. But when I looked at it, I thought "why wouldn't it just slide out the front if I move everything out of the way?". I'm glad I tried it, hope this helps you through the process. Don't buy the injector until you swap them and confirm that it is the injector, no reason to spend $80 on a part if it's not going to fix the problem.
	[Reply w/Quote]

10-04-2008, 11:01 PM	#23
tg900 Dialed! Age: 22 Join Date: May 2006 Posts: 723 Location: PA User is: OffLine	Re: How To: Injector Swap for 98+ meh i took my intake manifold off because i was hoping to do a cavi intake setup at the time..but the a/c blower box got in the way so all i did is change injectors and not intake.
	[Reply w/Quote]

10-05-2008, 12:27 PM	#24
duaneb9729 Registered User Age: 51 Join Date: Apr 2008 Posts: 12 Location: User is: OffLine	Re: How To: Injector Swap for 98+ does the fuel pressure regulator fit thru the intake manifold? or do you have to remove it? how does it come off? i removed the torx screw but i didnt have any luck getting it off the rail but i was reluctant to pull to hard or pry.
	[Reply w/Quote]

10-06-2008, 05:32 PM	#25
orangedime It Burns When I Pee Age: 27 Join Date: Mar 2007 Posts: 512 Location: Burlington, VT User is: OffLine	Re: How To: Injector Swap for 98+ Quote: Originally Posted by duaneb9729 does the fuel pressure regulator fit thru the intake manifold? or do you have to remove it? how does it come off? i removed the torx screw but i didnt have any luck getting it off the rail but i was reluctant to pull to hard or pry. I didn't have a regulator on mine, maybe you can include a picture and someone can help you out. This is a picture of what I pulled out as a full assembly
	[Reply w/Quote]

10-07-2008, 04:12 PM	#26
tg900 Dialed! Age: 22 Join Date: May 2006 Posts: 723 Location: PA User is: OffLine	Re: How To: Injector Swap for 98+ The flex fuel models dont have a regualtor on the fuel rail...its in the fuel fuel sensor located right near the coilpacks If you really need a picture I can take some this weekend...I got all kinds of fuel rails at home
	[Reply w/Quote]

08-18-2009, 06:30 PM	#27
fossunit43 Registered User Age: 18 Join Date: Nov 2008 Posts: 23 Location: User is: OffLine	Re: How To: Injector Swap for 98+ To bring this thread back to life, i would like some info on that fuel pressure regulator and how to get it off. Thanks
	[Reply w/Quote]

08-20-2009, 12:25 AM	#28
dirty_drew Registered User Age: 18 Join Date: Jul 2009 Posts: 122 Location: Iowa City, Iowa User is: OffLine	Re: How To: Injector Swap for 98+ I ended up using a light dab of motor oil to lube it up instead of vaseline.
	[Reply w/Quote]

08-20-2009, 11:21 PM	#29
Nitestoker Registered User Age: 50 Join Date: Aug 2009 Posts: 5 Location: Hays Ks User is: OffLine	Re: How To: Injector Swap for 98+ Nice info, I will be performing surgery soon.
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