Removal Procedure
Wear safety glasses in order to avoid eye damage.
Fuel/gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
When working on the fuel rail and fuel injectors, always maintain a clean work surface. Failure to maintain a clean work surface can result in contaminant on the injector seals and cause leaks.
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (KL9)
- Ignition Coil - Remove [ 4x ] - Ignition Coil Replacement
- Fuel Injection Fuel Rail Wiring Harness @ Engine Wiring Harness - Disconnect
- Fuel Feed Intermediate Pipe - Remove - Fuel Feed Intermediate Pipe Replacement
Adjust the length (a) of one EN-51146 - 1 - 6 demounting screw (1) to match the length (b) of one NEW fuel injector bolt (2).
Install the EN-51146 - 1 - 6 demounting screw (1) into a EN-51146 - 1 - 1 support (2) and tighten to 7 N.m (62 lb/in).
Repeat the previous instructions for a total of eight EN-51146 - 1 - 6 demounting screw and EN-51146 - 1 - 1 support combinations (1).
- NOTE:
- Do NOT loosen or remove both the inner and outer fuel injector bolts at the same time on any single fuel injector.
- Ensure the EN-51146 - 1 - 6 demounting screw and the EN-51146 - 1 - 1 support combination is properly installed in the inner fuel injector bolt hole before removing the corresponding outer fuel injector bolt.
At Cylinder 1, remove and DISCARD the inner fuel injector bolt (1).
- Install the EN-51146 - 1 - 6 demounting screw and EN-51146 - 1 - 1 support combination (2) into the inner fuel injector bolt hole and tighten to 5 N.m (44 lb/in).
At Cylinder 1, remove and DISCARD the outer fuel injector bolt (1).
- Install the EN-51146 - 1 - 6 demounting screw and EN-51146 - 1 - 1 support combination (2) into the outer fuel injector bolt hole and tighten to 5 N.m (44 lb/in).
In order, from Cylinder 1 to Cylinder 4, repeat the previous instructions to install the remaining EN-51146 - 1 - 6 demounting screw and EN-51146 - 1 - 1 support combinations (1).
LOOSEN the upper fuel injection fuel rail bolts (1) completely from the cylinder head, but do NOT remove the bolts from the bolt retainers.
- LOOSEN the lower fuel injection fuel rail bolts (2) completely from the cylinder head, but do NOT remove the bolts from the bolt retainers.
Position the EN-51146 - 100 plate (1).
- Use a suitable wrench (2) to hold each EN-51146 - 1 - 1 support (3) and tighten each corresponding plate bolt (4) to 5 N.m (44 lb/in).
- NOTE:
- The alignment of the fuel injectors within the cylinder head bores is CRITICAL for fuel injection system function.
- ALWAYS use equal force on each slide hammer to ensure the fuel injectors are removed from the cylinder head bores without tilting.
Install the EN-51146 - 1 - 3 slide hammers (1) to the EN-51146 - 100 plate (2) and apply slight upwards force equally to both hammers to remove the fuel injection fuel rail and fuel injectors as an assembly (3).
Observe the alignment of the fuel injection fuel rail and fuel injectors while removing and allocate more force to the hammers as necessary.
- NOTE:
- After removing the fuel injection fuel rail and fuel injectors, position the assembly on a clean work surface with the fuel injectors pointing upwards.
- Do NOT allow the weight of the fuel injection fuel rail to rest on the fuel injectors.
Install the EN-51146 - 2 - 5 calibration tools (1) onto the fuel injector tips to protect the injectors.
- Remove the EN-51146 - 1 - 3 slide hammers (2).
- Cover the cylinder head bores to prevent any contamination.