Fuel Injector: Service and Repair

LEGEND:
1. Fuel supply line
- 25 Nm (18 ft lb.)
2. Fuel return line
- 25 Nm (18 ft lb.)
3. Fuel pressure regulator
4. O-ring
- Always replace
5. Vacuum unit for cruise control
6. 20 Nm (15 ft lb.)
7. Retaining clip for fuel injector
8. Air-shrouded fuel injector
- Always replace O-ring

NOTE: When replacing O-ring, do not remove cap.

9. 10 Nm (7 ft lb.)
10. Fuel rail
11. 10 Nm (7 ft lb.)
12. Vacuum hose
13. Retaining clip for fuel pressure regulator

OBSERVE:
- Safety precautions. Service Precautions
- Rules of cleanliness. Vehicle Damage Warnings

NOTES:
- Always replace seals and gaskets.
- Before starting repairs,
^ Check Diagnostic Trouble Code (DTC) memory. Refer to "How to Display and Read Diagnostic Trouble Codes" at "On-Board Diagnostics II". Testing and Inspection
^ Check output Diagnostic Test Mode (DTM). Refer to "Diagnosis With Scan Tool, Address Word 01" at "On-Board Diagnostics II". Testing and Inspection

REMOVAL:
- Remove intake air duct between air cleaner housing and throttle valve.
- Remove engine cover.
- Remove accelerator pedal cable at bracket.
- Remove ball joint at connecting linkage for cruise control.
- Move accelerator pedal cable over cruise control vacuum unit toward rear.
- Disconnect vacuum hose for cruise control vacuum unit.
- Disconnect vacuum hose from fuel pressure regulator.
- Disconnect harness connector for engine coolant temperature sensor (blue connector).
- Disconnect harness connectors for knock sensors.
Remove cable ties or retaining straps as necessary.
- Disconnect connector for intake manifold change~overvalve.
- Disconnect harness connectors for fuel injector air valve.
- Disconnect harness connectors from fuel injectors.
Remove cable ties or retaining straps as necessary.
- Remove fuel rail from intake manifold and lift off together with fuel injectors.
- Disconnect hose from air valve for fuel injectors.

INSTALLING:
Installation of the fuel rail and the fuel injectors is the reverse of removal. Also observe to following special points:

- Replace all O-rings at all connections that have been opened. (To replace the front O-ring, do not remove the plastic cap from the valve head. Slip the O-ring over the plastic cap).
- Lubricate O-rings with clean engine oil.
- Install fuel injectors upright to stop (open connectors must face outward) and secure injectors with retaining clips.
- Place fuel rail with installed fuel injectors into position at intake manifold and press in to stop.
- Insert bolts by hand. Lightly push fuel rail by hand toward intake manifold and tighten bolts to 10 Nm (7 ft lb.).
- Check fuel injectors for correct installation position (open electrical connectors face outward).
- Check to see that fuel injector retaining clamps are properly seated.