Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect Battery Negative Cable Disconnection and Connection (with KL9)Battery Negative Cable Disconnection and Connection (without KL9)
- Remove Ignition Coil Replacement
- Disconnect Fuel Injection Fuel Rail Wiring Harness.
- Remove Fuel Feed Intermediate Pipe Replacement
- Match the length (a) of the EN-51146-1-6 demounting screws (1) to the length of the fuel injector bolt (2).
- Install the EN-51146-1-6 demounting screws (2) to the EN-51146-1-1 supports (1) and tighten to 7 N.m (62 lb in).
- Remove and DISCARD the inner fuel injector Bolt (1).
- Install one EN-51146-1-6 demounting screws and EN-51146-1-1 support (2) and tighten to 5 N.m (44 lb in).
- Remove and DISCARD the outer fuel injector bolt (1).
- Install a second EN-51146-1-6 demounting screws and EN-51146-1-1 support (2) and tighten to 5 N.m (44 lb in).
- Using the same procedure, install the remaining EN-51146-1-6 demounting screws and EN-51146-1-1 supports (1) for each fuel injector and tighten to 5 N.m (44 lb in).
- Loosen the 4 upper fuel rail assembly bolts (1) completely from the cylinder head, but do not remove the bolts.
- Loosen the 4 lower fuel rail assembly bolts (2) completely from the cylinder head, but do not remove the bolts.
- Install EN-51146-100 plate (2) to the EN-51146-1-1 supports (1) using the eight plate bolts (3). Counterhold each support with a wrench while tightening the bolt.
- Install the EN-51146-1-3 slide hammers (4) onto the EN-51146-100 plate (2) using the outer holes.
- Using the EN-51146-1-3 slide hammers (1, 2), begin to remove the fuel injectors by applying slight force equally on both hammers. Observe the alignment of the fuel injectors, and allocate force on the hammers as necessary.
- Complete the removal of the fuel rail and injector assembly with the EN-51146 remover. The slide hammers may then be removed from the plate.
- Install the EN-51146-2-5 calibration tools onto the fuel injector tips to protect the injectors.
- Cover the fuel injector bores at the cylinder head to prevent contamination.
Refer to Gasoline/Gasoline Vapors Warning .
Maintain a clean work surface when working with fuel rail and fuel injectors. Use care to avoid contaminants on the injector seals.
Remove only one fuel injector bolt (2) to perform the length check.
Refer to Fastener Caution .
Do not loosen or remove both fuel injector bolts for an individual fuel injector at the same time. Ensure the EN-51146-1-6 demounting screw and EN-51146-1-1 support is properly installed on the inner fuel injector bolt location before removing the remaining outer fuel injector bolt. Ensure the bolts do not fall into the cylinder head slot.
The fuel rail bolts may remain with the decoupling elements and retainer at the fuel rail assembly.
The alignment of the fuel injectors within the cylinder bores is critical for fuel injection system function. Use equal force on each slide hammer to ensure the fuel injectors are removed without tilting in the injector bore.
After removing the fuel rail and injector assembly, position the assembly on a clean work surface with the fuel injectors on top. Do not allow the weight of the assembly to rest on the fuel injectors.