Fuel Injector: Service and Repair

FUEL RAIL

Part 1:

Part 2:

Exploded View

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure, even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury.

Both Sides
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.

RH side
3. Remove the wiring harness retainer from the RH valve cover stud bolt and position it aside.
4. Disconnect the 3 fuel injector electrical connectors.
5. Remove the 2 fuel rail supply tube bolts from the RH side fuel rail.
- To install, tighten to 6 Nm (53 lb-in).

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

Remove and discard the fuel rail supply tube O-ring seal.

7. Remove the 2 bolts and the RH side fuel rail.
- To install, tighten to 23 Nm (17 lb-ft).

8. Remove the 3 fuel injectors from the fuel rail.

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

Remove and discard the fuel injector O-ring seals.

LH side
10. Disconnect the fuel rail pressure and temperature sensor vacuum hose.
11. Disconnect the fuel rail pressure and temperature sensor electrical connector.
12. Remove the wiring harness retainer from the LH valve cover stud bolt and position it aside.
13. Disconnect the 3 fuel injector electrical connectors.
14. Remove the 2 fuel rail supply tube bolts from the LH side fuel rail.
- To install, tighten to 6 Nm (53 lb-in).

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

Remove and discard the fuel rail supply tube O-ring seal.

16. Remove the 2 bolts and the LH side fuel rail.
- To install, tighten to 23 Nm (17 lb-ft).

17. Remove the 3 fuel injectors from the fuel rail.

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

Remove and discard the fuel injector O-ring seals.

Both Sides
19. To install reverse the removal procedure.
- Lubricate the new O-ring seals with clean engine oil prior to installation.