Fuel Injector: Service and Repair

FUEL RAIL

Part 1:

Part 2:

Exploded View

Removal

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 may 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury.

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







3. Remove the 2 nuts, the bolt and the generator air inlet duct.
4. Disconnect the fuel tube quick connect coupling from the fuel rail.
5. Detach the 2 wiring retainers from the fuel rail and remove the fuel rail insulator.
6. Disconnect the 2 swirl control valve electrical connectors.
7. Disconnect the 4 fuel injector electrical connectors.
8. Remove the 2 fuel rail bolts.
9. Remove the fuel rail and fuel injectors as an assembly.
10. Remove the 4 fuel injector retainer clips and the fuel injectors.
- Remove and discard the 8 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.
- Make sure the fuel rail clips snap back into place.

Install the fuel injectors and the retainer clips into the fuel rail.

2. Install the fuel rail and fuel injectors as an assembly.
3. Install the 2 fuel rail bolts.
- Tighten to 23 Nm (17 lb-ft).

4. Connect the 4 fuel injector electrical connectors.
5. Connect the 2 swirl control valve electrical connectors.
6. Install the fuel rail insulator and attach the 2 wiring harness retainers.
7. Connect the fuel tube quick connect coupling to the fuel rail.







8. Install the generator air inlet duct and the 2 nuts and the bolt.
- Tighten to 6 Nm (53 lb-in).

9. Connect the battery ground cable.