How to remove/install injectors... - Mitsubish Lancer Evolution Forum

turbolarry · 04-09-2005, 10:47 AM

First you want to relieve fuel pressure in the system. To do this by disconnecting the fuel pump, while the car is running and trying to start it several times after. To do this you want to;
Pull on the tabs in front of the rear seat and lift the seat cousin up. Under the driver's side rear seat is the fuel pump assembly cover plate.

turbolarry · 04-09-2005, 10:48 AM

Remove the four screws and lift the cover plate.

turbolarry · 04-09-2005, 10:49 AM

Start the car and leave it in idle with the emergency break on. Go back to the rear seat and unplug the gray plug to the fuel pump assembly. Remember to press on the tab on the top of the plug. The car will run for a couple of more seconds, then die. Try to start the car several times. I try to start it three times. This will remove more fuel from the system.

turbolarry · 04-09-2005, 10:51 AM

Now to the engine bay.
Remove the BOV vacuum source at the manifold and tuck it aside.

turbolarry · 04-09-2005, 10:52 AM

Remove the boost source to the fuel pressure regulator and tuck it aside.

turbolarry · 04-09-2005, 10:54 AM

Get some rags because fuel is going to come out. Slide the clamp on the fuel return line back, remove the fuel return line at this point, and tuck it aside.

turbolarry · 04-09-2005, 10:55 AM

Remove the two 10mm bolts at the fuel feed line. This is a little difficult to reach and requires an extension. In this photo it's difficult to see, but I used a 10mm deep socket, a 6 inch extention, and then the ratchet. Get some more rags, then rotate the flange on the feed line and give it a tug. It should come out with an O-ring.

turbolarry · 04-09-2005, 11:00 AM

With a small, small screwdriver (the kind for glasses size) remove the retaining clips on the injector plugs. It’s a small wire that goes around the injector. Be careful too because one jumped and disappeared on me. I spent a good hour searching the engine bay and floor looking for the clip, only to give up and see it was on the windshield. Once the wire clip is off the plug slides right off the injector.

turbolarry · 04-09-2005, 11:04 AM

With a 12mm deep socket remove the two fuel rail bolts (this one in the photo and one hiding behind the fuel return line bracket). Hold on to the small black plastic spacers as you remove the bolts. It’s no fun searching for these either. Get some more rags and remove the entire assembly, fuel rail, with injectors attached, fuel pressure regulator and the small section of return line. Check the injector ports to make sure the insulators came out too. Your going to use the new insulators your injectors came with.

turbolarry · 04-09-2005, 11:14 AM

This is where the batteries for my camera died. I'll try and get some more ASAP, but this part is pretty basic

Once the assembly is all out, hold on to the fuel rail and twist and pull on the injectors. They should come off with their O-rings. Install your new injectors into the fuel rail with new O-rings, which requires a little lube (oil, nose grease, spit, whatever’s handy). Twist the injector into the fuel rail, kinda screw it in to keep the O-ring from tearing. Same thing on the fuel feed line O-ring too.

Install everything on the reverse order.

Remember the black spacers and the injector insulators.

Torque the fuel rail bolts to (tight) 98 ± 8 in-lb
Torque the fuel feed line bolts to (snug) 44 ± 9 in-lb

Make basic adjustments to your fuel controller if your installing larger than stock injectors.

Once everything is back in, and remember to connect the fuel pump assembly, and start the car. With a flash light look for leaks at the injector ports, along the fuel rail, and the fuel feed and return lines. If you don't see any leaks, and most importantly, you don't smell any fuel, your done.