Regan Brown
Honda's Programmed Fuel Injection (PGM-FI) is a digital electronic multi-point injection system for internal combustion engines. Introduced in the early 1980s, it has been used in motorcycles, automobiles, and outboard motors. The PGM-FI system relies on a piezoelectric sensor to measure intake manifold air pressure, which is then combined with crankshaft rpm and other data to calculate air quantity. While the system is generally reliable, issues with fuel injectors can occur, requiring their removal and replacement. This process involves disconnecting the negative battery cable, relieving fuel pressure, unplugging electrical connectors, and carefully pulling out the fuel injector.
Removing the Fuel Injector on PGM-FI
| Characteristics | Values |
|---|---|
| Step 1 | Disconnect the negative battery cable |
| Step 2 | Relieve the fuel pressure |
| Step 3 | Unplug the electrical connectors from the fuel injectors |
| Step 4 | Disconnect the vacuum hose and fuel return hose from the fuel pressure regulator |
| Step 5 | Disconnect the fuel line from the fuel pipe |
| Step 6 | Remove the fuel pipe retainer nuts and the fuel pipe |
| Step 7 | Pull out the fuel injector |
| Step 8 | Remove the seal after the injector has been pulled out |
| Reinstallation | Slide new cushion rings onto the injectors. Coat new O-rings with clean engine oil and install them on the injectors |
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What You'll Learn
Disconnect the negative battery cable
Disconnecting the negative battery cable is an important first step when removing a fuel injector on a PGM-FI system. This is a safety measure to prevent any accidental electrical discharge or short circuits during the removal process.
To begin, locate the negative battery cable. It is typically black in colour and is usually clearly marked. The cable will be connected to the negative terminal of the battery, which will also be marked with a '-' symbol or the word "NEG" to indicate negative polarity.
Once you have identified the negative battery cable, proceed to carefully disconnect it from the battery terminal. Ensure that you are wearing protective gloves and eye protection before beginning this step. Use a suitable tool, such as a wrench or a pair of pliers, to loosen the nut or bolt securing the cable to the terminal. Slowly and gently remove the cable to avoid any sparks or damage to the cable or terminal.
Place the disconnected cable in a safe location away from any conductive materials or sources of heat or sparks. It is important to ensure that the cable does not accidentally come into contact with the positive terminal or any other power source during the fuel injector removal process.
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Unplug electrical connectors
To unplug the electrical connectors from the fuel injectors, first relieve the fuel pressure and disconnect the negative battery cable. Then, use a thin pick to disengage the metal spring clip that secures the fuel injector electrical connectors. Be sure to place a rag or shop towel over the hose and tube before disconnecting them.
It is important to note that the process of unplugging the electrical connectors may vary slightly depending on the specific make and model of the vehicle, as well as the design of the fuel injection system. For example, the 1992-95 design may have slight differences in the fuel injector mounting and fuel rail components compared to other models.
Additionally, when working on any fuel system, it is crucial to take the necessary safety precautions, such as wearing protective gear and ensuring proper ventilation. It is also important to refer to the vehicle's repair manual or seek assistance from a qualified technician if you are unsure about any steps in the process.
By following these steps and taking the necessary precautions, you can safely and effectively unplug the electrical connectors from the fuel injectors in a PGM-FI system.
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Disconnect the vacuum hose and fuel return hose
To disconnect the vacuum hose and fuel return hose, you must first relieve the pressure in the fuel system. Next, locate the vacuum hose and fuel return hose connected to the fuel pressure regulator. Place a rag or shop towel over the hose and tube before disconnecting them. Then, disconnect the vacuum hose and the fuel return hose from the fuel pressure regulator.
The vacuum hose is a large (3/8 in) PCV vacuum hose that can be found from the front of the intake manifold plenum (a large silver box with a label PGM-FI). It turns toward the passenger side and then down between the intake manifold tubes/runners to the PCV valve. The hose is a cooling bypass hose that makes a big horseshoe and attaches under the front of the intake manifold.
The fuel return hose is likely made of plastic and can be found behind the engine along the firewall. It is important to note that the fuel return hose is durable and can hold up to 250 pounds per square inch of pressure. However, plastic hoses are subject to breakage if the hose moves. Therefore, it is recommended to replace the fuel return hose if there are any signs of damage or leaking fuel. Symptoms of a failing return hose include a flooded carburetor, leaking fuel, or the smell of gas around the car.
To remove the fuel return hose, use a fuel hose quick disconnect tool to disconnect and remove the hose from the fuel return hose extension. Be careful when removing plastic fuel lines as they may break easily.
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Remove the fuel pipe retainer nuts
To remove the fuel pipe retainer nuts, you must first disconnect the negative battery cable. Ensure that the fuel system pressure has been relieved before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Next, disconnect the vacuum hose and fuel return hose from the fuel pressure regulator. Place a rag or shop towel over the hose and tube before disconnecting them for safety. Now, disconnect the fuel line from the fuel pipe. Then, disconnect the EACV from the intake manifold. Finally, you can remove the fuel pipe retainer nuts and the fuel pipe.
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Pull out the fuel injector
To pull out the fuel injector, you will need to first relieve the fuel pressure in the lines. It is hazardous to open a pressurized fuel line. Open the fuse box on the driver's side fender well and remove the fuel pump fuse or relay. You can find the location of the fuses and relays at the bottom of the fuse block lid. If it is not there, consult the owner's manual. Attempt to start the engine. If it starts, let it run until it is out of fuel, then turn off the key. After running the engine, the fuel pressure will be relieved.
Next, remove the air cleaner and intake air hoses as necessary to gain access to the fuel rail. You will need to lift the fuel rail off of the intake manifold, bringing the injectors with it. This takes a good amount of force, as the injectors are attached to the rail, and the sprayer tips fit snugly in the intake manifold. Do not use so much force that you deform or bend the fuel rail. Pulling straight up (as the injector is oriented) makes for easier removal.
Before pulling out the fuel injector, disconnect the negative battery cable. Then, examine the injector. If you see a small metal clip that looks like a staple, use a small flathead screwdriver to remove or depress the clip. Now, while wearing gloves, grasp the injector and work it back and forth while pulling to remove it from the fuel rail. The injector and rail will drip, so have shop towels ready.
Finally, carefully pull out the fuel injector. You may notice carbon buildup from the combustion chamber.
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Frequently asked questions
PGM-FI stands for Programmed Fuel Injection, a system developed by Honda for internal combustion engines.
Here is a simplified version of the process:
- Disconnect the negative battery cable.
- Relieve the fuel pressure.
- Unplug the electrical connectors from the fuel injectors.
- Disconnect the vacuum hose and fuel return hose from the fuel pressure regulator.
- Disconnect the fuel line from the fuel pipe.
- Remove the fuel injector.
Honda's PGM-FI system has been used in a variety of their automobiles, including the 1980s City Turbo, Accord, and Prelude models, as well as the 2014 Odyssey and 2015 Civic.
Some common issues include error codes, warning lights, and fuel injector control module errors.
Yes, it is important to relieve the fuel pressure before disconnecting any fuel lines or hoses. It is also crucial to disconnect the negative battery cable before beginning any work.
