I
just completed this task. I would suggest not removing the upper
intake unless you just can't get around it. It is not hard, just time
consuming. You will have to move most of your accesories out of the way
(alternator and A/C, remove the upper fan shroud and the power steering
pulley along with the A/C mounting bracket) If you are having the
common intake coolant leak problem, I suggest you also spring for a new
set of intake bolts. Be careful how tight you torque evrything, remember its aluminum.
After disassembly make sure evrything is super clean, if you scrape the intake be careful not to scratch or gouge it.
When you go back together you will need to be very careful of how you
position the intake, the front and rear seals are RTV Black and you must
clear some obstacles near the rear of the engine so you can place the
intake square and straight down on the block.
Before you begin the process of replacing a fuel injector or fuel injection rail, you need to think about safety. Always keep fire safety in mind when you are working with fuel. You also need to be sure you are wearing eye protection. Even if you've released the pressure in the fuel injection system, there could be some fuel flying when you start disconnecting high pressure lines and removing injectors.First, disconnect the main fuel line at the end of the rail. There may be an additional line at the other end, so remove that one, too. The fuel rail is help in place by screws or bolts, depending on your car's setup. Remove these screws or bolts. If your wiring travels over the top of the rail, see the next step to disconnect the wiring first. With everything disconnected from the rail, pull it away from the fuel injectors. Most fuel rails are just pressed onto the injector tops, once you've removed the hold down screws or bolts it should pull away, with a little oomph.If your car uses a fuel rail to deliver fuel to the injectors, you removed it in the previous step. If you don't have a fuel rail, you'll need to remove a fuel line from the top of each injector. It's just as easy to remove, just do it carefully.
With the fuel delivery out of the way, you're ready to disconnect the fuel injectors. Each injector will have a plug at the top (or on the side near the top) that connects to the wiring harness. Most fuel injector wiring plugs are held securely in place by a springy wire (see pic). To remove this wire, just insert a flat head screwdriver in the space between the spring and the plug and pry it carefully away. It will come out easily. Don't lose it!With all of the other stuff out of the way, you're ready to yank the injector. Unfortunately, many people really do try to yank them out. Remember, your fuel injectors sit right in the middle of the delicate are of the engine, so any piece you break off might fall in, and this equals big pain in your fanny.
The safest way to remove a fuel injector is to use a fuel injector puller. There are other ways to remove fuel injectors, but if you aren't careful you could damage some expensive fuel injection components. Besides, the injector puller makes it so easy, just slide it underneath the lip in the injector housing and pop the injector out.
Your fuel injector goes into what amounts to a hole in the intake manifold (or your head if you're lucky). When you remove the injector, you leave this hole open. Be very careful to keep anything from falling in. This can be a real chore to fix.
In the immortal words of every auto repair tutorial, installation is the reverse of removal! You'll need to lubricate the new injector seals before they go in, and remember to go easy, don't force anything in.
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why is fuel leaking out through upper intake
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