Fuel Injector: Service and Repair

FUEL RAIL

Exploded View







Removal

WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the upper intake manifold.
4. Disconnect the fuel supply tube quick connect coupling at the fuel rail.
5. Disconnect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
6. Disconnect the 6 fuel injector electrical connectors.
7. Remove the 4 fuel rail bolts.
8. Detach the fuel charging wiring harness retainers from the fuel rail and remove the fuel rail and injectors as an assembly.
9. Remove the 6 fuel injectors.
- Remove and discard the 12 fuel injector O-ring seals.

Installation

1. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Install new fuel injector O-ring seals and lubricate them with clean engine oil.

Install the fuel injectors.

2. Position the fuel rail and install the bolts.
- Tighten to 10 Nm (89 lb-in).

3. Attach the fuel charging wiring harness retainers to the fuel rail.
4. Connect the 6 fuel injector electrical connectors.
5. Connect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
6. Connect the fuel supply tube quick connect coupling at the fuel rail.
7. Install the upper intake manifold.
8. Connect the battery ground cable.