Fuel Rail: Service and Repair

REMOVAL

CAUTION:
^ Apply new engine oil when installing the parts that specified to do so in the figure.
^ Do not remove or disassembly parts unless instructed as shown above.

1. Release the fuel pressure. Refer to Fuel Pressure Release.
2. Disconnect the accelerator cable and speed control cable (if equipped) from the throttle body.
3. Disconnect the intake manifold bracket.

CAUTION:
^ Prepare a container and a cloth to catch any spilled fuel.
^ This operation should be performed in a place free from any open flames.
^ While hoses are disconnected seal their openings with vinyl bag or similar material to prevent foreign material from entering them.

4. Remove the PCV hose and bracket.
5. Disconnect the sub-harness for the fuel injectors.
6. Disconnect the fuel pressure regulator vacuum hose from the intake manifold collector.
7. Disconnect the fuel hoses from the fuel tube assembly.
8. Remove the fuel injectors from the fuel tube, as follows:
^ Release the clip, and remove the fuel injector.
^ Pull the fuel injector straight out of the fuel tube.
^ Be careful not to damage the nozzle.
^ Avoid any impact, such as dropping the fuel injector.
^ Do not disassemble or adjust the fuel injector.

INSTALLATION
1. Installation is in the reverse order of removal.
^ Install new O-rings on the fuel injectors and the fuel pressure regulator.
^ Lubricate the new O-rings lightly with new engine oil.
^ Be careful not to scratch the injector during installation. Also be careful not to twist or stretch the O-ring. If the O-ring was stretched while it was installed, do no insert it into the fuel tube immediately.





a. Install the fuel injector into the fuel tube with the following procedure:
^ Do not reuse the clip, replace it with a new one.
^ Insert the clip into the clip mounting groove on the fuel injector.
^ Insert clip so that projection A of fuel injector matches notch A of the clip.
b. Insert fuel injector into fuel tube with clip attached.
^ Insert it while matching it to the axial center.
^ Insert fuel injector so that projection B of fuel injector matches notch B of the clip.
^ Make sure that fuel tube flange is securely fixed in flange fixing groove on the clip.
^ Make sure that installation is complete by checking that fuel injector does not rotate or come off.
c. Install the fuel tube assembly with the following procedure:
^ Insert the tip of each fuel injector into the intake manifold.





^ Tighten the fuel tube mounting bolts in two stages in the numerical order shown.
Stage 1: 12 - 13 Nm (1.2 - 1.4 kg-m, 9 - 10 ft. lbs.)
Stage 2: 17 - 23 Nm (1.7 - 2.4 kg-m, 13 - 17 ft. lbs.)

CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.

INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1. Start the engine and run it for a few minutes at idle.
2. Stop the engine and check for fuel leakage both visually and by odor of gasoline.

NOTE: Use mirrors for checking on hard to see points of the fuel system.

CAUTION: Do not touch the engine immediately after stopping, as the engine becomes extremely hot.