Fuel Rail and Injectors

REMOVAL & INSTALLATION

Except 1995–98 2.0L Non-Turbo Engines

1. Properly relieve the fuel system pressure as outlined earlier in this section.
2. For 1990–94 vehicles, disconnect the PCV hose from the valve cover. On 1.8L engines, also disconnect the breather hose at the opposite end of the valve cover.
3. For 1995–98 vehicles, tag and disconnect the spark plug wires.
4. Remove the bolts holding the high pressure fuel line to the fuel rail and disconnect the line. Be prepared to contain fuel spillage; plug the line to keep out dirt and debris.
5. Remove the vacuum hose from the fuel pressure regulator.
6. Disconnect the fuel return hose from the pressure regulator. Remove the fuel pressure regulator mounting bolts and remove from the fuel rail.
7. On 1990–94 2.0L engines, remove the clamps holding the accelerator cable and remove the center engine cover from between the cam cover.

   Fig. 1: On 1990–94 2.0L engines, there is a center cover which must be removed for access to the fuel rail

8. Label and detach the injector electrical connectors.
9. Remove the bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Be very careful not to drop any of the injectors. Place the rail and injectors in a safe location on a clean workbench; protect the tips of the injectors from dirt and/or impact.
10. Remove and discard the injector insulators from the intake manifold. The insulators are not reusable.
11. Remove the injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.

    Fig. 2: Exploded view of the fuel injectors and related components — 1.8L engine

    Fig. 3: Fuel rail and injector mounting — 1995–98 2.0L turbo and 2.4L engine

    To install:

12. Install a new insulator in each injector port in the manifold.
13. Remove and discard the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean engine oil.

    Fig. 4: Place a new grommet and O-ring on each injector

14. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting holes and tighten the retaining bolts to 8 ft. lbs. (11 Nm). This procedure must be followed even if the fuel rail was not removed.
15. Install the injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.

    Fig. 5: The fuel injector must be properly installed in the fuel rail

16. Install the delivery pipe and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
17. Install the fuel rail retaining bolts and tighten them to 8 ft. lbs. (11 Nm). On 2.0L engines, install the accelerator cable retaining clips before the rail retaining bolts.
18. Connect the wiring harnesses to the appropriate injector.
19. On 1990–94 2.0L engines, reinstall the center cover. Tighten the retaining bolts to 3 ft. lbs. (4 Nm).
20. Connect the fuel return hose to the pressure regulator, then connect the vacuum hose.
21. Replace the O-ring on the high pressure fuel line, coat the O-ring lightly with clean, thin oil and install the line to the fuel rail. Tighten the mounting bolts to 4 ft. lbs. (6 Nm).
22. If disconnected, attach the spark plug wires as tagged during removal.
23. If removed, connect the PCV hose and the breather hose.
24. Connect the negative battery cable. Pressurize the fuel system by turning the ignition ON and inspect all connections for leaks.

1995–98 2.0L Non-Turbo Engines

1. Properly relieve the fuel system pressure as outlined earlier in this section.
2. Disconnect the negative (if not already done), and the positive battery cables, then remove the battery from the vehicle.
3. Disconnect the air intake hose.
4. Place a shop rag around the fitting, then detach the high-pressure fuel hose connection. Remove and discard the line O-ring.
5. Unfasten the fuel return hose connection.

   Fig. 7: After relieving system pressure, loosen the high pressure fuel line

   Fig. 8: Make sure to place a shop rag under the line to catch any fuel that may seep out after disconnection

6. If necessary, disconnect the pressure regulator vacuum hose and the injector harness connector.

   Fig. 9: Unplug the fuel injector harness connector

7. Remove the fuel rail from the vehicle with the injectors attached. Be very careful not to drop the assembly. Place the rail and injectors in a safe location on a clean workbench; protect the tips of the injectors from dirt and/or impact.
8. Tag and detach the fuel injector electrical connectors.
9. Unfasten the injector-to-fuel rail retainers, then separate the injectors from the rail.

   Fig. 10: After the fuel rail is removed, spread the retainer and remove the fuel injector

10. Remove and discard the injector O-rings. There is 1 at each end of the O-ring.

    Fig. 11: As shown with arrows, there is an O-ring at the end of each injector

    Fig. 12: The injector O-rings must be discarded and replaced with new ones before installation

11. If necessary to remove the fuel pressure regulator, unfasten the snapring, then remove the pressure regulator from the fuel rail. Remove and discard the regulator O-rings.

    To install:

    WARNING
    When lubricating O-rings, do NOT allow any engine oil to get into the fuel rail!

12. If the regulator was removed, lightly lubricate new O-rings with clean engine oil, then install on he regulator. Position the regulator on the rail, then secure with the snapring.
13. Lightly coat new O-rings with clean engine oil, then install on the injector.
14. Install the injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage. Secure with the injector retainers.
15. Attach the injector electrical connectors, as tagged during removal.
16. Install the fuel rail into the vehicle and install the mounting bolts (if equipped).
17. Attach the injector harness connector and the pressure regulator vacuum hose.
18. Install the fuel return hose connection.
19. Install a new O-ring, then connect the high pressure fuel line. To ease connection, place a small amount of clean engine oil into the hose union before inserting.
20. Connect the air intake hose.
21. Install the battery, then connect the positive and negative battery cables.
22. Pressurize the fuel system by turning the ignition ON and inspect all connections for leaks.