Fuel Rail: Service and Repair
FUEL INJECTOR AND FUEL TUBE
Removal and Installation
CAUTION:
^ Apply new engine oil when installing the parts as specified to do so.
^ Do not remove or disassemble parts unless instructed as shown.
REMOVAL
1. Remove the engine cover using power tool.
2. Perform the Fuel Pressure Release Procedure.
3. Remove air cleaner case lid and mass air flow sensor, and air intake tub as an assembly.
4. Partially drain the coolant when the engine is cool.
WARNING: To avoid the danger of being scalded, never drain the coolant when the engine is hot.
5. Disconnect fuel tube quick connector at vehicle piping side.
6. Disconnect the power brake booster vacuum hose, the coolant hoses from the electric throttle control actuator, the swirl control vacuum lines, the fuel injectors electrical connectors, and the PCV hose.
CAUTION:
^ Cover any engine openings to avoid the entry of any foreign material.
7. Disconnect the electric throttle control actuator electrical connector and coolant hoses.
8. Remove the cowl top grille and the windshield wiper assembly.
9. Disconnect the power steering hose bracket.
10. Remove the vacuum tank from the back of the intake manifold collector.
11. Remove the intake manifold collector pipe and electric throttle control actuator, by loosening the four bolts in a diagonal pattern.
CAUTION: Handle carefully to avoid any shock to the electric throttle control actuator.
12. Loosen the bolts in the order shown, and remove the intake manifold collector using power tool.
13. Remove the fuel rail with the fuel injectors attached, from the intake manifold. Remove the fuel injector O-rings and use new O-rings for installation.
INSTALLATION
1. Install the fuel rails with fuel injectors attached.
NOTE:
^ Carefully install new O-rings, including the one used with the fuel damper.
^ Lubricate O-rings by lightly coating with new engine oil.
^ Be careful not to damage the O-rings and surfaces for O-ring sealing surfaces. Do not expand or twist O-rings.
^ Discard old clips; replace with new ones.
^ Make sure that protrusions of fuel injectors are align installation.
^ Position clips in grooves on the fuel injectors.
^ Align the protrusions of the fuel tube assembly with those of the fuel injectors.
^ After properly inserting the fuel injectors onto the fuel tube assembly, check that the fuel tube protrusions are engaged with those of fuel injectors, and the flanges of the fuel tube assembly are fully engaged with the clips.
2. Tighten fuel tube assembly mounting bolts as shown in two steps:
1st step: 9.3 - 10.8 Nm (0.95 - 1.1 kg-m, 6.2 - 7.9 ft. lbs.)
2nd step: 20.6 - 26.5 Nm (2.1 - 2.7 kg-m, 16 -19 ft. lbs.)
CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.
3. Install the intake manifold collector bolts in the numerical order as shown.
Intake manifold collector bolts: 18 - 21 Nm (1.8 - 2.2 kg-m, 13 - 15 ft. lbs.)
4. Tighten the mounting bolts of the intake manifold collector pipe and electric throttle control actuator assembly diagonally to specification.
Intake manifold collector pipe bolts: 18 - 21 Nm (1.8 - 2.2 kg-m, 13 - 15 ft. lbs.)
5. After installation, it is necessary to re-calibrate the electric throttle control actuator.
6. Attach the quick connector.
7. Installation of remaining components is in the reverse of removal.
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections as follows:
1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.
NOTE: Use mirrors for checking on connections out of the direct line of sight.
CAUTION: Do not touch engine immediately after stopping as engine is extremely hot.
^ Perform procedures for "Throttle Valve Closed Position Learning" after finishing repairs.
^ If electric throttle control actuator is replaced, perform procedures for "Idle Air Volume Learning" after finishing repairs.