### Fuel Injector

#### REMOVAL AND INSTALLATION

##### 1.6L (GA16DE) Engine

Fig. 1: Fuel injector assembly — 1.6L (GA16DE) engine

1. Relieve the fuel system pressure and disconnect the negative battery cable.
2. Disconnect the fuel injector wiring harness connectors and the vacuum line from the fuel pressure regulator.
3. Disconnect the fuel hoses from the fuel rail assembly.
4. Remove the bolts that secure the entire fuel rail to the intake.
5. Remove the injectors with the fuel rail assembly.
6. Remove the individual injector by removing the bolts that secure the cap to the injector.
7. Remove the injector from the fuel rail by pushing the injector from the bottom and discard the O-rings.

   WARNING
   DO NOT remove the injector by pulling on the electrical connector.

   To install:

8. Install new O-rings onto the injectors and coat the O-rings with clean fuel.
9. Install the injector into the fuel rail assembly and install the cap that secures the injector. Tighten the cap bolts to 26–33 inch lbs. (3–4 Nm).
10. Install the insulators, injectors, and the fuel rail assembly to the intake manifold. Torque the retaining bolts in sequence and in two (2) steps. Torque the bolts to 15–20 ft. lbs. (20–27 Nm).

    Fig. 2: Fuel rail torque sequence — 1.6L (GA16DE) engine

11. Install the fuel hoses with new clamps to the fuel rail.
12. Connect the fuel injector wiring harness connectors and the vacuum line to the fuel pressure regulator.
13. Connect the negative battery cable.
14. Start the engine and check for fuel leaks after the installation is complete.

##### 2.0L (SR20DE) Engine

1. Release the fuel system pressure and disconnect the negative battery cable.
2. Disconnect all fuel and vacuum hoses and electrical harnesses from the pressure regulator and fuel rail.
3. Remove the injector/fuel rail assembly.
4. Push out the injector from the bottom of the fuel rail assembly.

   WARNING
   DO NOT remove the injector by pulling on the electrical connector.

   To install:

5. Always replace the O-rings and insulators with new. Lubricate the O-rings with fuel.
6. Install the injectors to the fuel rail and tighten the cap that secures the injector to 26–33 inch lbs. (3–4 Nm). Install the rail onto the intake manifold.
7. Torque the fuel rail bolts as follows:
   1. Tighten all bolts in sequence to 8 ft. lbs. (11 Nm).
   2. Tighten all bolts in sequence to 15–20 ft. lbs. (21–26 Nm).
8. Connect the fuel hoses with new clamps and the connect vacuum lines. Connect the injectors to the harness.
9. Connect the battery cable, start the engine, and check for leaks before road testing.

##### 2.4L (KA24DE) Engine

1. Relieve the fuel system pressure.

   CAUTION
   Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

2. Disconnect the negative battery cable.
3. Note the locations of the vacuum hoses and disconnect the hoses from the intake manifold.
4. Note the connector locations and remove the injector electrical harness connections.
5. Disconnect the fuel feed and return lines from the fuel rail.
6. Remove the bolts that secure the fuel rail to the intake and remove the rail with injectors.
7. Remove the screws that secure the cap to the individual injectors and remove the cap.
8. Push the injector tail piece to remove the injector from the tube assembly. Do not pull on the connector.

   To install:

   NOTE: When replacing the fuel injectors always use new O-rings.

9. Clean the exterior of the injector tailpiece.
10. Push the injectors into the fuel tube and secure with cap.
11. Install the fuel tube and injectors assembly into the engine.
12. Using new clamps, reconnect the fuel lines to the fuel rail.
13. Reconnect the injectors electrical harness and the vacuum hoses.
14. Reconnect the negative battery cable.
15. Start the engine and check for leaks.

##### 3.0L (VE30DE) Engine

1. Relieve the fuel system pressure.
2. Remove the intake manifold collector.
3. If necessary, disconnect the electrical connectors from the ignition coils.
4. If necessary, disconnect the electrical connector from the crank angle sensor and the power transistor.
5. Remove the fuel injector assembly by performing the following procedures:
   1. Disconnect the electrical connectors from the fuel injectors.
   2. Disconnect the fuel injector assembly from the fuel lines.
   3. Remove the fuel rail-to-cylinder head bolts.
   4. Remove the fuel rail assembly from the engine.
6. To remove the fuel injector from the fuel rail, remove the fuel injector-to-fuel rail bolts and remove the fuel injector from the fuel rail; discard the O-rings.

   To install:

7. To install the fuel injector to the fuel rail, perform the following procedures:
   1. Install new O-rings onto the fuel injector.
   2. Wet the new O-rings with fuel and press the injector into the fuel rail.
   3. Install the bolts and tighten the fuel injector retainer.
8. Clean the gasket mounting surfaces.
9. Install the fuel injector assembly by performing the following procedures:
   1. Install the fuel rail assembly to the engine.
   2. Install the fuel rail-to-cylinder head bolts and torque the bolts to 12–14 ft. lbs. (16–20 Nm).
   3. Connect the fuel injector assembly to the fuel lines.
   4. Connect the electrical connectors to the fuel injectors.
10. The remaining components are installed in the reverse order from which they were removed.
11. Refill the cooling system and connect the negative battery cable.
12. Start the engine, bleed cooling system and check for leaks.

##### 3.0L (VG30E) Engine

1. Relieve the fuel system pressure.
2. Remove the upper and lower intake manifold collector.
3. Remove the fuel injector assembly by performing the following procedures:
   1. Disconnect the electrical connectors from the fuel injectors.
   2. Disconnect the fuel injector assembly from the fuel lines.
   3. Remove the fuel rail-to-cylinder head bolts.
   4. Remove the fuel rail assembly from the engine.
4. To remove the fuel injector from the fuel rail, remove the fuel injector-to-fuel rail bolts and the fuel injector from the fuel rail; discard the O-ring.

   To install:

5. To install the fuel injector to the fuel rail, perform the following procedures:
   1. Install a new O-ring onto the fuel injector.
   2. Wet the new O-ring with fuel and press the injector into the fuel rail.
   3. Install the bolts and tighten the fuel injector retainer.
6. Clean the gasket mounting surfaces.
7. Install the fuel injector assembly by performing the following procedures:
   1. Install the fuel rail assembly to the engine.
   2. Install the fuel rail-to-cylinder head bolts and torque the bolts to 1.8–2.4 ft. lbs. (2–3 Nm).
   3. Connect the fuel injector assembly to the fuel lines.
   4. Connect the electrical connectors to the fuel injectors.
8. Use a new gasket and install the lower intake manifold collector.
9. balance of installation is the reverse of the removal procedure.
10. Connect the negative battery cable.
11. Start the engine and check for leaks.

##### 3.0L (VQ30DE) Engine

1. Release the fuel system pressure.

   CAUTION
   The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

2. Disconnect the negative battery cable and drain the cooling system.
3. Remove the intake manifold collector.
4. Remove the fuel injector assembly by performing the following procedures:
   1. Disconnect the electrical connectors from the fuel injectors.
   2. Disconnect the fuel lines from the fuel injector assembly.
   3. Remove the fuel rail-to-cylinder head bolts.
   4. Remove the fuel rail assembly from the engine.
5. To remove the fuel injector from the fuel rail, remove the fuel injector-to-fuel rail bolts and remove the fuel injector from the fuel rail; discard the O-rings.

   To install:

6. To install the fuel injector to the fuel rail, perform the following procedures:
   1. Install new O-rings onto the fuel injector.
   2. Wet the new O-rings with fuel and press the injector into the fuel rail.
   3. Install the bolts and tighten the fuel injector retainer to 27–33 inch lbs. (3–4 Nm).
7. Clean the gasket mounting surfaces.
8. Install the fuel injector assembly by performing the following procedures:
   1. Install the fuel rail assembly to the engine.
   2. Install the fuel rail-to-cylinder head bolts and torque the bolts to 15–20 ft. lbs. (21–26 Nm) in two progressive steps.
   3. Connect the fuel lines to the fuel injector assembly.
   4. Connect the electrical connectors to the fuel injectors.
9. Using a new gasket, install the intake manifold collector.
10. Install the remaining components in the opposite order from which they were removed.
11. Refill the cooling system and connect the negative battery cable.
12. Start the engine, bleed cooling system, and check for leaks.

##### 3.0L (VG30DE and VG30DETT) Engines

CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

1. Disconnect the negative battery cable, drain the cooling system, and release the fuel system pressure.
2. Remove the intake manifold collector.
3. Disconnect the electrical connectors from the ignition coils.
4. Disconnect the electrical connector from the crank angle sensor and the power transistor.
5. Disconnect the electrical connectors from the fuel injectors.
6. Disconnect the fuel injector assembly from the fuel lines.
7. Remove the fuel rail-to-cylinder head bolts.
8. Remove the fuel rail assembly from the engine.
9. Remove the bolts that secure fuel injector to the fuel rail.
10. Gently pull the fuel injector from the fuel rail and disregard the O-ring.

    To install:

    NOTE: When the fuel injector is remove the injector sealing O-rings must be replaced.

11. Clean the gasket mounting surfaces.
12. Using new O-rings, install the fuel injector to the fuel rail and torque the mounting bolts to 22–28 inch lbs. (2–3 Nm).
13. Install and tighten the fuel rail-to-cylinder head bolts. Be sure to install the fuel rail insulators.
14. Using new clamps, connect the fuel lines to the fuel rail assembly.
15. Connect the electrical connectors to the fuel injectors.
16. Connect the electrical connectors to the ignition coils.
17. Using a new gasket, install the intake manifold collector.
18. The remaining components are installed in the reverse order from which they were removed.
19. Connect the negative battery cable.
20. Refill the cooling system.
21. Start the engine, bleed the cooling system, and check for leaks.