### Fuel Injectors/Rail Assembly

#### REMOVAL & INSTALLATION

##### 200SX (Z-Series Engine)

Fig. 1: Top: removing the Z-series fuel pressure regulator to fuel pipe screws. Bottom: Fuel pipe assembly retaining screws

Fig. 2: Removing the fuel pipe and injector assembly — Z series engine

Fig. 3: Removing the injector securing screws.

Fig. 4: Fuel pressure regulator location and connections

NOTE: Review the entire procedure before starting this repair.

1. Release fuel pressure by following the correct procedure. Refer to Fuel Pressure Release Procedure.
2. Disconnect the negative battery cable and the accelerator cable.
3. Disconnect the injector harness connector.
4. Tag and disconnect the vacuum hose at the fuel pipe connection end. Disconnect the air regulator and its harness connector, and tag and disconnect any other hoses that may hinder removal of the injection assembly.
5. Disconnect the fuel feed hose and fuel return hose from the fuel pipe.

   NOTE: Place a rag under the fuel pipe to prevent splashing of the fuel.

6. Remove the vacuum hose connecting the pressure regulator to the intake manifold.
7. Remove the bolts securing the fuel pipe and pressure regulator.
8. Remove the screws securing the fuel injectors. Remove the fuel pipe assembly, by pulling out the fuel pipe, injectors and pressure regulator as an assembly.
9. Unfasten the hose clamp on the injectors and remove the injectors from the fuel pipe.

   To install:

10. Install the fuel injectors in the fuel pipe with new hose clamps.
11. Install the fuel pipe assembly, injectors with new O-rings and pressure regulator as an assembly.
12. Connect the fuel feed hose and fuel return hose to the fuel pipe. Use new hose clamps on all connections. Reconnect all vacuum hoses and electrical connections.
13. Reconnect the accelerator cable and battery cable. Note the following:
    1. When installing the injectors, check that there are no scratches or abrasion at the lower rubber insulator, and securely install it, making sure it is air-tight.
    2. When installing the fuel hose, make sure the hose end is inserted onto the metal pipe until the end contacts the unit, as far as it will go. Push the end of the injector rubber hose onto the fuel pipe until it is 25mm from the end of the pipe.
    3. Never reuse hose clamps on the injection system. Always renew the clamps. When tightening clamps, make sure the screw does not come in contact with adjacent parts.
14. Start the engine and check for fuel leaks.

##### 200SX (CA Series Engine)

NOTE: On the CA20E engine on late model 200SX vehicles the collector assembly may NOT have to be removed — modify Step 2 of the service procedure below.

1. Release fuel pressure by following the correct service procedure. Refer to Fuel Pressure Release Procedure. Disconnect the negative battery cable.
2. On the CA20E engine, drain the engine coolant. Disconnect the fuel injection wiring harness, the ignition wires, and remove the collector with the throttle chamber. Tag and disconnect all related hoses.
3. On the CA18ET engine, disconnect the air intake pipe, the fuel injection wiring harness, the ignition wires and accelerator cable. Remove the throttle chamber.

   Fig. 5: Injector assembly — CA20E/CA18ET Engines

   Fig. 6: Injector assembly and fuel pressure regulator — CA20E/CA18ET Engines

   Fig. 7: Fuel injector and related hardware. When replacing injector always replace the lower rubber (1) and upper rubber insulator (3)

   Fig. 8: Always replace the hose clamps. Note proper installation

4. On all engines, disconnect the fuel hoses and pressure regulator vacuum hoses.
5. Remove the fuel injectors with the fuel rail assembly.
6. Remove the fuel injector hose-to-fuel rail clamp(s), then pull the injector from the fuel rail.

   To install:

7. To remove the fuel hose from the injector, use a hot soldering iron, then cut (melt) a line in the fuel hose (to the braided reinforcement), starting at the injector socket to 3⁄4 in. (19mm) long. Remove the hose from the injector, by hand.

   NOTE: DO NOT allow the soldering iron to cut all the way through the hose, nor touch the injector seat or damage the plastic socket connector.

8. To install a new fuel hose, clean the injector tail section, wet the inside of the new hose with fuel, push the hose into the fuel injector hose socket (as far as it will go) retain it with a new hose clamp if necessary. Assemble the injector(s) onto the fuel rail.
9. Install the injectors with new O-rings and fuel rail as an assembly.
10. Connect the fuel hoses and pressure regulator vacuum hoses.
11. On the CA18ET engine, connect the air intake pipe, the fuel injection wiring harness, the ignition wires and accelerator cable. Install the throttle chamber.
12. On the CA20E engine, reconnect the fuel injection wiring harness, the ignition wires, and install the collector with the throttle chamber if necessary. Reconnect all related hoses and refill the cooling system if necessary.
13. Reconnect the battery cable. Start the engine and check for fuel leaks.

##### 200SX (VG30 Engine)

1. Release fuel pressure by following the correct procedure. Refer to Fuel Pressure Release Procedure. Disconnect the negative battery cable.
2. Disconnect these items at the intake collector: the air intake duct; accelerator linkage; PCV hose; air regulator pressure hose; B.C.D.D. hose; fuel hoses; E.G.R tube; wiring harness clamps; wiring harness connectors; intake collector cover. Then, drain some coolant out of the cooling system and disconnect the coolant hoses connecting into the collector.

   Fig. 9: Removing the intake collector cover — 200SX (VG30E engine)

   Fig. 10: Removing the intake collector — 200SX (VG30E engine)

   Fig. 11: Removing the fuel tube securing bolts — 200SX (VG30E engine)

   Fig. 12: Removing the fuel injector/pressure regulator assembly — 200SX (VG30E engine)

   Fig. 13: Removing the fuel injector hose

   Fig. 14: Removing the intake collector cover gasket — 200SX (VG30E engine)

3. Remove the intake collector assembly.
4. Remove the bolts securing the fuel tube.
5. Remove the bolts securing the injectors and remove the injectors, fuel tubes, and pressure regulator as an assembly.

   To install:

6. To remove the fuel hoses, heat a sharp knife until it is hot. Cut into the braided reinforcement from the mark on the hose to the end of the fuel tube connection.

   NOTE: Make sure the knife does not cut all the way through the hose and nick the injector tail piece or connector fitting.

7. Pull the hose off of the injectors. DO NOT install the injectors in a vise to hold them as you pull off the hoses.
8. To install new hose, clean the exterior of the injector tail piece and the end of the fuel tube with a safe solvent. Then, wet the inside diameter of the new hose with fuel. Push the ends of the hoses and fittings onto the injector tail piece and the end of the fuel tube as far as they will go by hand, retain it with a new hose clamp if necessary
9. Assemble the injector(s) onto the fuel rail. Install the injectors with new O-rings and fuel rail as an assembly.
10. Install the intake collector assembly.
11. Connect the air intake duct; accelerator linkage; PCV hose; air regulator pressure hose; B.C.D.D. hose; fuel hoses; E.G.R tube; wiring harness clamps; wiring harness connectors and intake collector cover to the collector assembly.
12. Connect the coolant hoses to the collector and refill the cooling system to the proper level.
13. Reconnect the battery cable. Start the engine and check for fuel leaks.

##### 240SX

NOTE: On the KA24DE engine on late model 240SX vehicles the BPT valve may NOT have to be removed — modify Step 3 of the service procedure below.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove the BPT valve.
4. Remove the fuel tube retaining bolts.
5. Remove the fuel tube and injector assembly from the intake manifold.
6. Withdraw the injectors from the fuel tube.

   To install:

7. Clean the injector tail piece and insert the injectors into the fuel tube with new O-rings.
8. Position the injector and fuel tube assembly onto the intake manifold and install the injector tube retaining bolts.
9. Pressurize the fuel system and check for leaks at all fuel connections.
10. Install the BPT valve if necessary.
11. Connect the negative battery cable.

##### Stanza (CA Series Engine)

NOTE: On the CA20E engine on late model Stanza vehicles the collector assembly may NOT have to be removed — modify Step 4 of the service procedure below.

1. Refer to the Fuel Pressure Release Procedure in this section and reduce the fuel pressure to zero. Disconnect the negative battery cable.
2. Remove the fuel inlet and outlet hoses from the fuel rail.

   Fig. 15: Fuel injector and rail assembly

   Fig. 16: Fuel injector and rail assembly

3. Disconnect the EFI electrical harness from the fuel injectors and the vacuum hose from the fuel pressure regulator, located at the center of the fuel rail.
4. Remove the fuel rail securing bolts, the collector/throttle chamber (if necessary) and the injector securing bolts.
5. Remove the fuel injectors with the fuel rail assembly.
6. Remove the fuel injector hose-to-fuel rail clamp(s), then pull the injector from the fuel rail.

   To install:

7. To remove the fuel hose from the injector, use a hot soldering iron, then cut (melt) a line in the fuel hose (to the braided reinforcement), starting at the injector socket to 3⁄4 in. (19mm) long. Remove the hose from the injector, by hand.

   NOTE: DO NOT allow the soldering iron to cut all the way through the hose, nor touch the injector seat or damage the plastic socket connector.

8. To install a new fuel hose, clean the injector tail section, wet the inside of the new hose with fuel, push the hose into the fuel injector hose socket (as far as it will go). Assemble the injector(s) onto the fuel rail.
9. Install the injectors with new O-rings and securing bolts.
10. Install the collector and the throttle chamber if necessary and the fuel rail securing bolts.
11. Connect the EFI electrical harness to the fuel injectors and the vacuum hose to the fuel pressure regulator.
12. Connect all the fuel lines.
13. Start engine and check for fuel leaks.

##### Stanza (KA24E Engine)

1. Relieve fuel pressure from system. Disconnect the negative battery cable.
2. Remove or disconnect the following:
   1. Air duct
   2. Fuel hoses
   3. Pressure regulator
   4. Accelerator wire bracket
   5. Injector harness connectors
3. Remove the bolts securing the fuel tube.
4. Remove bolts securing injectors and remove injectors and fuel tube as an assembly.
5. Reverse the service procedure to install.