2003 Safari - Removing Injectors from Lower Manifold

[paulo57509]

I searched around here for a while and couldn't find a definitive answer for this question.

I'm in the process of replacing a faulty injector (#3 cylinder) on my '03 Safari and I'm stumped as far as removing them from the lower manifold. the FSM says to squeeze the tabs. No such tabs on these. Some say to just pry and wiggle. What is the proper procedure?

Attached is a photo of the injector in question. AC Delco P/N 217-1516

TIA

[Corsemoto]

I haven't had to do any injector service on my 2004 Astro AWD so not sure, I'm used to dealing with motorcycle injectors where they are seated with an o-ring and retaining screw.

You can also save money by having your fuel injectors flow tested and cleaned. For not much more than the price of one new AC Delco fuel injector you could have all of them serviced. I have had much success with this type of service for motorcycle fuel injectors where racing fuels (left sitting too long) have clogged or damaged the injectors. Here's one type of this service (no prior experience with them): http://www.injectorrx.com



Here is what the Chilton online manual shows:

Removal & Installation
Before servicing the vehicle, refer to the Precautions Section.
Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section.
Remove engine cover.
Disconnect negative battery cable.
Remove upper manifold assembly.
Disconnect fuel meter body electrical connection and the fuel feed and return hoses from the engine fuel pipes.
Remove poppet nozzle out of the casting socket by squeezing the nozzle locking tabs together.
Remove fuel meter body by releasing the locktabs.
NOTE
Each injector is calibrated. When replacing the fuel injectors, be sure to replace it with the correct injector.
Remove lower hold-down plate and nuts.
While pulling the poppet nozzle tube downward, push with a small prytool down between the injector terminals and remove the injectors.



To install:
Lubricate the new injector O-ring seats with engine oil.
Install o-rings on the injector.
Install fuel injector into the fuel meter body injector socket.
Install lower hold-down plate and nuts. Torque the nuts to 27 inch lbs. (3 Nm).
Install fuel meter body assembly into the intake manifold. Torque the fuel meter bracket retainer bolts to 88 inch. lbs. (10 Nm).
CAUTION
To reduce the risk of fire or injury ensure that the poppet nozzles are properly seated and locked in their casting sockets.
Install fuel meter body into the bracket and lock all the tabs in place.
Install poppet nozzles into the casting sockets.
Engage electrical connections.
Install new o-ring seals on the fuel return and feed hoses.
Connect fuel feed and return hoses and tighten the fuel pipe nuts to 22 ft. lbs. (30 Nm).
Connect negative battery cable.
Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
Install the engine cover.

[paulo57509]

I got the injectors out of the manifold by twisting and pulling. The plastic tabs on these injectors appear to be a one-shot deal; they don't "lock" the injector into place once they've been installed and removed and then re-installed. I just carefully bent them out and they again lock into place. I can't say that it'll be permanent, though. I doubt that it matters.

The van runs fins now (DTC's PO200, PO300B and PO303 were previously set).

Another gotcha with following the FSM: removing the cruise control cable from the throttle body arm. The FSM says not to remove the c-clip to remove the cable because you'll damage the cable end. It says to gently pry the cable end off the throttle body arm. Doing this also breaks the cable end.

[paulo57509]

....Another gotcha with following the FSM: removing the cruise control cable from the throttle body arm. The FSM says not to remove the c-clip to remove the cable because you'll damage the cable end. It says to gently pry the cable end off the throttle body arm. Doing this also breaks the cable end.

I found these on the Dorman web site. There are a couple of sellers on ebay as well.

http://www.dormanproducts.com/p-27391-41040.aspx

[Rob770]

The description from the manual you posted is for the central port fuel injection. I recently upgraded to multi point injection on my 97 safari. The old injectors have 2 little clips you squeeze and they come out. When I installed the MP injectors they looked exactly like yours and the directions said they cannot be removed without damaging them. Since you are replacing it, don't worry about damaging the clip. Give her a squeeze and a yank, it should come out.