General
Warning! Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions could result in death or serious injury.
Refer to the VRSCA Electrical Diagnostic Manual for information on the function and testing of the fuel injectors.
Removal
1. Remove airbox and air filter. See 1.4 Airbox and air filter.
Warning! To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.
2. Disconnect negative battery cable.
3. Loosen clamps at each intake and lift throttle body straight up.
Note. Observe the position of the clamps for reassembly.
Figure 1-15. Intake clamps (throttle body removed)
4. With throttle cables attached, wrap a shop towel around body for protection and secure away from engine.throttle body and fuel rail. See 3.9 Throttle body.
Disassembly
Fuel injectors
1. See Figure 9-16. Remove screw (7).
Figure 9-16. Fuel rail: 1. Fuel pressure regulator; 2. Fuel injector clip; 3. Front fuel injector; 4. Fuel pressure regulator clip; 5. Screw; 6. Rear fuel injector; 7. Screw; 8. Schrader valve 6.8-9.6 Nm (60.0-85.0 in-lbs); 9. Screw
2. Pull fuel injector and clip from induction module.
3. Remove clip from fuel injector.
4. Repeat procedure for other fuel injector.
Fuel pressure regulator
1. See Figure 9-16. Remove screws (5, 9).
2. Remove fuel pressure regulator clip (4) from fuel rail.
3. Use rocking motion to detach fuel pressure regulator (1) from fuel rail.
Fuel tubes
Note. Do not remove fuel tubes, о-rings or spacers if not replacing.
1. See Figure 9-16. Remove screws (9, 5).
2. Remove fuel pressure regulator clip (4) from fuel rail.
3. See Figure 9-17. Pull feed (4) and return (5) fuel tubes from fuel rail.
Figure 9-17. Fuel tubes: 1. Fuel rail; 2. O-ring; 3. Washer; 4. Feed fuel tube; 5. Return fuel tube
Assembly
Fuel injectors
1. Inspect fuel injector о-rings, replace if damaged
2. Apply clean engine oil to fuel injector o-rings.
3. Insert fuel injector into fuel rail.
4. Slide fuel injector clip into slot in fuel injector.
5. Secure with screw and tighten to 2.0-2.8 Nm (18.0-25.0 in-lbs).
6. Repeat for other fuel injector.
Fuel pressure regulator
1. Inspect fuel pressure regulator о-rings. Replace pressure regulator if о-rings are damaged.
2. Apply clean engine oil to fuel pressure regulator o-rings.
3. Install fuel pressure regulator into bore in fuel rail.
4. See Figure 9-16. Install fuel pressure regulator clip over fuel tubes.
5. Install screws (5, 9). Tighten to 2.0-2.8 Nm (18.0-25.0 in-lbs).
Fuel tubes
1. See Figure 9-17. Install washers (3) over fuel tube.
2. Apply clean engine oil to new fuel tube o-rings (2).
3. Install feed and return fuel tubes into proper holes in fuel rail.
4. See Figure 9-16. Install fuel pressure regulator clip over fuel tubes.
5. Install screws (5, 9). Tighten to 2.0-2.8 Nm (18.0-25.0 in-lbs).
Installation
1. Install fuel rail and throttle body. See 3.9 Throttle body.
2. Connect negative battery cable.
3. Install airbox and filter. See 1.4 Airbox and air filter.