Fuel Injector Replacement - Polaris Ranger RZR 800 Manual

ELECTRONIC FUEL INJECTION

Fuel Injector Replacement

1. Be sure the engine has cooled enough to work on.
2. Remove the seats and rear service panel: (see chapter 5)
• RZR / RZR S: Remove both driver and passenger seats
• RZR 4: Remove both rear passenger seats
3. Remove the rear cargo box (see chapter 5).
4. Place a suitable container below the quick connect plug at
the end of the fuel rail. Hold a shop rag over the plug and
remove it to depressurize the fuel system.
Fuel Rail
5. Disconnect the harness for the fuel injector(s) located next
to the ignition coil. Cut the plastic tie strap and push the
harness for the fuel injector(s) up over the air box to allow
fuel injector removal.
IMPORTANT: Take note of PTO and MAG fuel injector
harness connectors before disconnecting them. The
harnesses are different and can not be connected
incorrectly (PTO - Gray; MAG - Black).
Fuel Injector
Harnesses
4.18
NOTE: The harness connector and locking spring is
bonded to the fuel injectors with an epoxy. DO NOT
attempt to disconnect the Bosch connector from the
fuel injectors. Damage will occur to the injector and/
or harness if attempting to separate at that location.
Separate the fuel injector from the vehicle harness
as shown in the illustration below.
Quick Connect
Plug
6.
7.
8.
9.
Fuel
Disconnect Here
Injector
Harness
DO NOT
Disconnect Here
Thoroughly clean the area around the fuel injectors
including the throttle body manifold.
Using a 6 mm hex wrench, loosen the fuel rail mounting
screw from the cylinder head. Carefully pull the rail away
from the injectors and remove the injector(s) from the
cylinder head along with the harness.
Mounting
Screw
Fuel Injectors
Fuel Rail
Reverse the previous steps to install the new injector(s) and
reassemble.
Lubricate O-rings lightly with oil to aid installation. Torque
the fuel rail mounting screw to specification.
Fuel Rail Mounting Screw
216 +/- 24 in. lbs. (24 Nm)
= T