Step by step guide on how to replace an automotive engine fuel injector P0200,
P0201, P0202, P0203, P0204, P0205, P0206, P0207 and P0208 though appearances may
vary the process is similar for most vehicles.
Difficulty Scale: 4 of 10
Begin by parking the vehicle on level ground, engine off, with the parking brake
set. Also, gas will be present, please wear protective gloves, clothing and eye
wear for safety.
- Identify the fuel injector to be replaced,
injectors are subject to leakage and operational failures. If there is uncertainty
on which fuel injector has failed, a
test must be performed.
Step 2 - Begin by removing the electrical connector
from the fuel injector, some connectors have a safety clip that needs to be released
Step 3 - Then, remove the mounting bolts located
on each comer of the fuel rail, these locations can vary. This will enable the fuel
rail to be loosened and allow the fuel injector to be removed.
Remove Electrical Connector
Remove Fuel Rail Hold Down Bolts
Step 4 - Once the bolts have been removed, proceed
in gently lifting the fuel rail from the intake manifold, this will pop the rail
loose allowing the fuel injector to be removed from the intake manifold. (Note:
Occasionally it will be necessary to remove the fuel supply and return lines from
the fuel rail, its best to leave these connected to avoid fuel contamination when
Step 5 - After the fuel rail has been loosened,
apply pressure downward to the fuel injector from the rail, this will pop the injector
from the O ring seal located on either end of the injector. (Note: Some injectors
are held in by a retainer clip that must be removed.)
Lift Up On Fuel Rail
Remove Fuel Injector
Step 6 - Inspect the old fuel injector and account
for both sealing O rings as they can get stuck in the rail or down in the intake
Step 7 - The pintel valve located at the end of
the injector is where the fuel exits the injector and enters the engine, its common
for these valves to plug and stop working (small holes.)
Old Fuel Injector
Step 8 - The O ring seal is used at either end
of the injector and should be replaced when installing a new injector.
Injector Pintel Valve
Step 9 - Match the old fuel injector to the new
unit, they should match identically, remove the dust caps from either end and ensure
new O ring seals are installed.
Fuel Injector O Ring Seal
Step 10 - Gently install the new injector being
mindful of the O ring seals. (Note: Use lubricant on O ring seals when installing
New Fuel Injector
Step 11 - Once the new injector has been installed
back into the fuel rail, gently push down on the rail while aligning the remaining
Installing New Fuel Injector
Step 12 - Next, install rail mounting bolts and
Push Down On Fuel Rail
Step 13 - After the mounting bolts have been tightened,
reconnect the electrical connector to the fuel injector. Once the job is complete
inspect the fuel rail for leaks after the engine has been started and ran.
Reinstall Fuel Rail Mounting Bolts
A fuel injector is used to supply fuel to one or more cylinders. A multi-port
fuel injection system or TBI (throttle body injection) uses two fuel injectors to
feed six or eight cylinders and one injector to feed four cylinders. Direct port
injection or DPI uses one fuel injector for each cylinder. Each of these fuel injector
styles depend on a uniform spray pattern which requires on a constant fuel pressure
supply. Common injector failures include: leakage, short circuit and fully or partially
plugged pintel nozzle.
Tools and Supplies Needed
Reinstall Fuel Injector Electrical Connector
- Replacement fuel injector and O rings and gaskets
- Shop towels
- Socket and ratchet set.
- Wrench set.
- Screw driver set
- Replace the fuel filter when servicing a fuel injector
- Clean throttle bore
- Use new sealing O rings on the fuel rail
Article first published 2017-06-19