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Fuel Injection Fuel Rail Assembly Replacement

Fuel Injection Fuel Rail Assembly Replacement



Special Tools

• DT-2619-01 Slide Hammer

• EN-37281-A Injector Remover


For equivalent regional tools, refer to Special Tools .

Removal Procedure


1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

2. Remove engine sight shield. Refer to Engine Sight Shield Replacement .

3. Remove the intake manifold. Refer to Intake Manifold Replacement .

4. Disconnect the electrical harness from the fuel rail harness connection.


5. Remove the fuel injector noise insulator (1).

6.
Warning

Fuel coming from the tank under high pressure can cause serious injuries to the skin and eyes. ALWAYS relieve the pressure in the fuel system before removing components under high fuel pressure.


Remove and discard the high pressure fuel line (1).


7. Disconnect all 4 fuel injector electrical connections.


8. Remove the fuel rail fasteners.

9. Remove the fuel rail and fuel injectors (1).

10. The fuel injectors may stick in the cylinder head. Remove the fuel injector hold-down clamps before removing the fuel injectors.


11. Use the EN-37281-A remover (2) and the DT-2619-01 hammer to remove the fuel injectors (1).


Installation Procedure


1. Install the fuel rail with the fuel injectors into the cylinder head evenly.


2. Hand tighten the 2 outer fuel rail fasteners to seat the fuel injectors into the fuel injector bores.

3. Refer to Fastener Caution .

Start and hand tighten the remaining fuel rail fasteners.

4. Tighten the fuel rail fasteners in sequence to 22 Nm (16 lb ft) .

5. Tighten the fuel rail fasteners in sequence a second time to 22 Nm (16 lb ft) .

6. Install the fuel injector noise insulator (1).


7. Connect the electrical harness to the fuel rail harness connection.

8. Install and hand-tighten both ends of the NEW high pressure fuel line (1).


9. Tighten the high pressure fuel line fitting nuts to 30 Nm (22 lb ft) .

10. Install the intake manifold. Refer to Intake Manifold Replacement .

11. Install engine appearance cover replacement. Refer to Engine Sight Shield Replacement .


PRE-RELEASE