Fuel Rail

Fuel Rail





Removal and Installation

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.

WARNING: 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.

NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install plugs to any open orifices or tubes. Failure to follow these instructions may result in fuel injection component damage.

NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Failure to follow these instructions may result in fuel or vapor leaks and connector damage.

1. Disconnect the battery ground cable.

2. Remove the engine cover.

3. Remove the Air Cleaner (ACL) and the ACL outlet tube.

4. Release the fuel system pressure.

5. Disconnect the fuel tube quick connect coupling.





6. Disconnect the transmission wiring harness retainers from the engine wiring harness. Position the transmission wiring harness aside.





7. Disconnect the Throttle Position (TP) sensor electrical connector and the wiring harness retainer.





8. Disconnect the 10 fuel injector electrical connectors.

9. Disconnect the 10 ignition coil electrical connectors.





10. Disconnect the quick connect couplings and remove the PCV tube.





11. Disconnect the engine wiring harness retainer from the rear of the intake manifold.





12. Disconnect the 2 RH engine wiring harness retainers and position the wiring harness away from the fuel rail.





13. Disconnect the 3 LH engine wiring harness retainers and position the wiring harness away from the fuel rail.





14. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will ease removal of the fuel rail.

Remove the 4 bolts, separate the fuel rail from the 10 fuel injectors and remove the fuel rail.

15. Remove the fuel injectors from the intake manifold and discard the upper and lower fuel injector O-ring seals.

Installation

1. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak.

NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.

Install 20 new upper and lower O-ring seals onto the 10 fuel injectors.

2. Install the 10 fuel injectors into the intake manifold.

3. Position the fuel rail onto the fuel injectors and install the 4 bolts.
- To install, tighten to 10 Nm (89 lb-in).

4. Position the engine wiring harness and connect the 3 LH engine wiring harness retainers.





5. Position the engine wiring harness and connect the 2 RH engine wiring harness retainers.





6. Connect the engine wiring harness retainer to the rear of the intake manifold.





7. Position the PCV tube and connect the quick connect couplings.





8. Connect the 10 ignition coil electrical connectors.





9. Connect the 10 fuel injector electrical connectors.

10. Connect the TP sensor electrical connector and wiring harness retainer.





11. Position the transmission wiring harness and connect harness retainers to the engine wiring harness.





12. Connect the fuel tube quick connect coupling.





13. Install the ACL and the ACL outlet tube.

14. Install the engine cover.

15. Connect the battery ground cable.