Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Special Tools

J-43178 - Fuel Line Disconnect Tool

Removal Procedure

1. Discharge the fuel system pressure. Refer to Fuel Pressure Relief (Service and Repair).
Warning: Refer to Battery Disconnect Warning (Service Precautions).

2. Disconnect the cable from the negative battery terminal. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair)
3. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair).
4. Remove the air cleaner assembly. Refer to Air Cleaner Element Replacement (Service and Repair).




5. Remove the fuel tube from the fuel hose clamp.
6. Remove the fuel pipe clamp.
7. Wipe off any dirt on the fuel tube connector.




8. Hold the fuel tube connector (1) , and then install the J-43178 - disconnect
tool.
9. Turn the J-43178 - disconnect tool to align the retainer inside the fuel tube connector with the chamfered part of the J-43178 - disconnect
tool.
10. Insert the J-43178 - disconnect tool into the fuel tube and hold it. Then push the fuel tube connector toward the J-43178 - disconnect tool.
11. Mount the retainer of the fuel tube connector onto the chamfered part of the J-43178 - disconnect tool.




12. Slide the J-43178 - disconnect tool and fuel tube connector (2) together towards the fuel tube (3) until they make a "click" sound, and then disconnect the fuel tube.
13. Drain the fuel remaining inside the fuel tube.
14. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected part.




15. Disconnect the ventilation hose (1) from the ventilation valve.




16. Remove the 2 wire harness clamps (1, 2).
17. Disconnect the 4 fuel injector connectors (3, 4, 5, 6).




18. Remove the 2 bolts (1, 2), then remove the fuel delivery pipe together with the 4 fuel injectors.




19. Remove the 2 delivery pipe spacers (1, 2) from the cylinder head.
20. Remove the 4 insulators (3, 4, 5, 6) from the cylinder head.




21. Remove fuel injector assembly.
22. Pull the 4 fuel injectors out of the fuel delivery pipe.

Installation Procedure




1. Apply a light coat of oil to new O-rings (1), then install one onto each fuel injector.
2. Apply a light coat of oil to the part of the fuel delivery pipe which comes into contact with the O-ring of the fuel injector.
3. Apply a light coat of oil to the O-ring again, then install the right and left fuel injectors onto the fuel delivery pipe.
4. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring.




5. Install 4 new insulators (3, 4, 5, 6) to the cylinder head.
6. Install the 2 delivery pipe spacers (1, 2) onto the cylinder head.




7. Install the fuel delivery pipe (2) together with the 4 fuel injectors (1), then hand tighten the 2 bolts.
8. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring (3).





Caution: Refer to Fastener Caution (Fastener Caution).

9. Install the 2 bolts (1, 2) and tighten to 20 Nm (15 lb ft).




10. Connect the 4 fuel injector connectors (3, 4, 5, 6).
11. Install the 2 wire harness clamps (1, 2).





Note: Make sure that the paint mark and hose clamp are at the correct angle when installing the hose.

12. Connect the ventilation hose (1) to the ventilation valve.
13. Connect the fuel main tube.
14. Push the fuel tube connector until it makes a "click" sound.
15. Install the fuel pipe clamp.
16. Install the fuel tube to the fuel hose clamp.
17. Install the air cleaner assembly. Refer to Air Cleaner Element Replacement (Service and Repair).
18. Install the engine cover sub-assembly. Refer to Engine Cover Replacement (Service and Repair).
Warning: Refer to Battery Disconnect Warning (Service Precautions).

19. Connect the cable to the negative battery terminal.
20. Inspect for a fuel leak.