Fuel Injector: Service and Repair

FUEL RAIL












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 may 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 may result in personal injury.

CAUTION:
- 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 blanking plugs to any open orifices or tubes.
- 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.

1. Disconnect the battery ground cable.
2. Disconnect the fuel supply tube spring lock coupling.
3. Remove the air cleaner outlet pipe.
4. Disconnect the quick connect couplings and remove the crankcase vent tube.







5. Disconnect the generator wiring harness retainer from the air cleaner outlet pipe-to-throttle body (TB) adapter.
6. Remove the 4 bolts and the air cleaner outlet pipe-to-TB adapter.
- Lubricate the air cleaner outlet pipe-to-TB adapter seal with clean engine coolant prior to installation.
- To install, tighten to 10 Nm (89 lb-in).

7. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube.







8. Disconnect the electronic throttle control electrical connector.







9. Disconnect the throttle position (TP) sensor electrical connector.







10. Disconnect the heated PCV intake fitting electrical connector.
11. Disconnect the 8 fuel injector electrical connectors.
12. Remove the 4 fuel rail bolts.
- To install, tighten to 10 Nm (89 lb-in).

13. Remove the fuel rail and fuel injectors as an assembly.
14. Remove the 8 fuel injector-to-fuel rail locking clips.







15. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring can cause the fuel system to leak. Do not reuse the O-ring seals.
Lubricate the O-ring seals with clean engine oil prior to installation.

Separate the fuel injectors from the fuel rail.
- Discard the O-ring seals.

16. To install, reverse the removal procedure.
- Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation.