4.30
9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual
© Copyright TAYLOR-DUNN
FUEL INJECTOR REPLACEMENT
WARNING
Gasoline is extremely flammable and explosive under
certain conditions.
Always stop the engine and refuel outdoors or in a well
ventilated area.
Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where
gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately. Do not
induce vomiting.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can result
loss of consciousness or death in a short time.
Never drain the fuel when the engine is hot. Severe
burns may result.
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
CAUTION
It is possible for pressurized fuel to be present when
disconnecting the fuel line.
It is recommended to allow the vehicle to sit for a period
of one hour after shutting off the engine before
servicing the fuel pump. This allows the exhaust to cool
and fuel pressure to drop.
1. Tilt the cargo box.
2. Be sure the engine has cooled enough to work on.
3. Remove the seat and disconnect the negative battery
cable.
4. Thoroughly clean the fuel injector area if all dirt and
debris.
5. Hold a shop towel over the fuel line fittings and
remove the fuel supply line from the fuel rail.
6. Disconnect the harness from the fuel injector
q
.
7. Remove the two screws
e
that mount the fuel rail
w
to the cylinder head.
8. Carefully pull up on the fuel rail and injector to remove
them from the engine as an assembly. If the injector
stays in the cylinder head, grab the injector with your
fingers and gently pull and twist the injector unit to
remove from cylinder head. Take care not to damage
the fuel injector ends during removal.
9. Gently pull and twist to free the injector from the fuel
rail.
10. Upon installation of the new fuel injector, lightly
lubricate the injector O-rings to aid installation.
11. Install the new injector into the fuel rail. Be sure to
align boss in the injector with the slot in the fuel rail.
12. Thoroughly clean the area around the fuel injector
port on the cylinder head.
13. Lightly lubricate the injector O-rings and reinstall the
fuel rail / injector assembly into the cylinder head.
14. Install the fuel rail mounting screws and torque to
specification
TORQUE
Fuel Rail Mounting Screws:
7 ft-lbs (10 Nm)
Summary of Contents for G0-010-00
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