Fuel Injector - Single

Replacement of a single fuel injector on a 1966 Chevrolet Corvette 327ci V8 equipped with Rochester fuel injection (rare factory option).

Warnings

Tools required

Parts

• Fuel injector × 1 — Rochester RAM-JET fuel injector (match existing part number)
• Fuel injector O-ring kit × 1 — Use OEM specification
• Fuel injector retaining clip × 1 — Reuse unless damaged

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable to prevent electrical shorts
3. Allow engine to cool completely if recently operated
4. Place shop towels and fuel catch pan beneath work area
5. Identify which injector requires replacement (cylinders numbered 1-8, driver front to rear 1-3-5-7, passenger front to rear 2-4-6-8)

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pressure test port on the fuel rail. Attach fuel pressure gauge to the test port. Open the gauge bleed valve slowly to relieve system pressure into the fuel catch pan. Monitor gauge until pressure reads zero PSI. Close bleed valve and remove gauge. Alternatively, if no test port is accessible, carefully loosen the fuel supply line at the fuel rail slowly to bleed pressure, then retighten before proceeding.
2. 2

   Remove air intake components
   Remove the air cleaner assembly by loosening the wing nut at the center and disconnecting any vacuum lines or PCV connections. Set aside in a clean area. If necessary for access, disconnect the throttle linkage at the throttle body by removing the retaining clip and sliding the linkage rod free.
3. 3

   Disconnect injector electrical connector
   Locate the electrical connector on the target fuel injector. Press the locking tab and pull the connector straight off the injector. Do not pull on the wires themselves. If connector is stuck, spray with electrical contact cleaner and use needle nose pliers to gently wiggle free while pressing the release tab.
4. 4

   Remove fuel rail hold-down hardware
   Remove the 2 bolts securing the fuel rail to the intake manifold. Use a 3/8" socket and ratchet. Note the location of any brackets or ground straps attached to these bolts. Set hardware aside in organized manner for reinstallation.
5. 5

   Lift fuel rail
   Carefully lift the fuel rail straight up approximately 1-2 inches to create clearance for injector removal. The rail does not need to be completely removed. Support the rail with one hand or use a prop to hold it in the raised position. Be careful not to strain any still-connected fuel lines or electrical connectors to adjacent injectors.
6. 6

   Remove injector retaining clip
   Locate the wire retaining clip that secures the injector to the fuel rail. Use needle nose pliers or a flat blade screwdriver to compress the clip ends and slide it off the injector body. The clip slides along the injector axis. Inspect clip for damage or fatigue; replace if bent or weakened.
7. 7

   Extract fuel injector
   Grasp the fuel injector body firmly and pull straight up with steady pressure to remove it from the intake manifold bore. Use a slight twisting motion if the injector is stuck due to old O-rings. Residual fuel will drain from the injector and rail; catch with shop towels. Inspect the injector mounting bore in the intake manifold for debris or carbon buildup.
8. 8

   Clean injector bore and inspect sealing surfaces
   Use shop towels to wipe out the injector bore in the intake manifold. If carbon deposits are present, carefully clean with a wire brush, being careful not to let debris fall into the intake port. Inspect the fuel rail injector pocket for damage, cracks, or corrosion. Clean any old O-ring material from both the intake manifold bore and the fuel rail pocket.
9. 9

   Prepare new fuel injector
   Remove new fuel injector from packaging. Lubricate the new O-rings with clean engine oil or petroleum jelly. Install the lower O-ring into the groove on the injector nozzle end, and the upper O-ring into the groove near the electrical connector end. Verify both O-rings are seated properly in their grooves and not twisted.
10. 10

    Install new fuel injector
    Align the new fuel injector with the bore in the intake manifold. Push the injector straight down into the bore with firm, steady pressure until it is fully seated. The injector should sit flush with or slightly below the fuel rail mounting surface. Rotate the injector so the electrical connector faces the proper direction for easy connection.
11. 11

    Install injector retaining clip
    Slide the retaining clip over the injector body, positioning it in the groove between the upper O-ring and the electrical connector. Use needle nose pliers to compress the clip ends and ensure it snaps fully into place. Tug gently on the injector to verify the clip is holding it securely.
12. 12

    Reinstall fuel rail
    Lower the fuel rail carefully back into position, ensuring the new injector nozzle enters the fuel rail pocket squarely. Press down firmly on the rail to fully seat all injectors. Reinstall the 2 fuel rail mounting bolts, along with any brackets or ground straps. Torque bolts to 84-120 inch-lbs in a criss-cross pattern. Without a documented torque specification, tighten firmly but do not over-torque to avoid cracking the intake manifold.
13. 13

    Reconnect injector electrical connector
    Push the electrical connector onto the new fuel injector until it clicks into place. Tug gently on the connector to verify it is locked. Ensure the connector boot is fully seated against the injector body to keep out moisture and debris.
14. 14

    Reinstall air intake components
    Reconnect throttle linkage if it was disconnected, securing with the retaining clip. Reinstall the air cleaner assembly, reconnecting all vacuum lines and PCV connections in their original positions. Secure the air cleaner with the wing nut, tightening snugly but not over-torquing.
15. 15

    Reconnect battery and prime fuel system
    Reconnect the negative battery cable. Turn the ignition key to the ON position (do not start) for 5 seconds, then OFF. Repeat this cycle 3 times to allow the fuel pump to prime the system and pressurize the fuel rail. Inspect all connections around the new injector and fuel rail for fuel leaks. Wipe up any residual fuel with shop towels.

Reassembly

1. Double-check all electrical connections are fully seated and locked
2. Verify all fuel rail mounting bolts are tight and any brackets are properly reinstalled
3. Confirm throttle linkage moves freely through full range without binding
4. Ensure no tools or shop towels are left in engine compartment

Verification

• Start engine and allow to idle. Listen for smooth operation without misfires on the cylinder with the new injector
• Inspect the new injector and surrounding fuel rail area for any fuel leaks while engine is running
• Rev engine to 2000-2500 RPM briefly and verify no stumbling or hesitation
• Allow engine to reach operating temperature and recheck for leaks
• Test drive vehicle and verify normal acceleration and no check engine light or rough running
• After test drive, perform final visual inspection of injector area for any seepage or wetness

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