Infinity_FX35_FX45_2003-2005

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3.5L Engine


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Fig. Exploded view of the fuel injector and rail assembly-3.5L engine



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Fig. Quick connect coupling detail for under-floor piping-3.5L engine



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Fig. Quick connector release use on fuel line couplings-3.5L engine



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Fig. Fuel rail assembly mounting bolt tightening sequence-3.5L engine



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Fig. Fuel injector detail and O-ring positioning-3.5L engine



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Fig. Install the quick connector so that the arrows face the fuel feed tube-3.5L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Release fuel pressure.
  6.  
  7. Remove the fuel feed hose (with damper) from the fuel sub-tube.
    NOTE
    There is no fuel return route.


    CAUTION
    While the hoses are disconnected, plug them to prevent fuel from draining. Also, do not separate the damper and hose.

  8.  
  9. When separating the fuel feed hose (with damper) and the centralized under-floor piping connection, disconnect the quick connector, as follows:
    1. Remove the quick connector cap from the quick connector connection on the right member side.
    2.  
    3. Disconnect the fuel feed hose (with damper) from the bracket hose clamp.
      CAUTION
      Disconnect the quick connector by using quick connector release too SST: (J-45488) or equivalent, not by picking out the retainer tabs.

    4.  
    5. With the sleeve side of the quick connector release facing the quick connector, install the quick connector release onto the centralized under-floor piping.
    6.  
    7. Insert the quick connector release into the quick connector until the sleeve contacts and goes no further. Hold the quick connector release at that position.
      CAUTION
      Inserting the quick connector release hard will not disconnect the quick connector. Hold the quick connector release where it contacts and goes no further.

    8.  
    9. Draw and pull out the quick connector straight from the centralized under-floor piping.
      CAUTION
      When disconnecting the fuel line, heed the following:



      Pull the quick connector holding A position as shown in the figure. Do not pull it with lateral force applied. The O-ring inside the quick connector may be damaged.
       
      Prepare a container and cloth beforehand as fuel will leak out.
       
      Avoid fire and sparks.
       
      Keep parts away from all heat sources. Especially, be careful when welding is performed around them.
       
      Do not expose the parts to battery electrolyte or other acids.
       
      Do not bend or twist the connection between the quick connector and the fuel feed hose (with damper) during installation/removal.
       
      To keep the connecting portion clean and to avoid damage from foreign materials, cover them completely with plastic bags or something similar.
       

    10.  

  10.  
  11. Remove the upper and lower intake manifold collectors.
  12.  
  13. Disconnect the wiring harness connector from the fuel injector.
  14.  
  15. Loosen the mounting bolts in the reverse order shown, and remove the fuel tube and fuel injector assembly.
    CAUTION
    Do not tilt the assembly, or the remaining fuel may leak.

  16.  
  17. Remove the fuel injectors from fuel the tube with the following procedure:
    1. Open and remove the clip.
    2.  
    3. Remove the fuel injector from the fuel tube by pulling straight.
      CAUTION
      During injector removal, heed the following items:



      Be careful with the remaining fuel that leaks from the fuel tube.
       
      Be careful not to damage the injector nozzles during removal.
       
      Do not bump or drop the fuel injectors.
       
      Do not disassemble the fuel injectors.
       

    4.  

  18.  
  19. Remove the fuel sub-tube and fuel damper.
  20.  

To install:


CAUTION
When handling all O-rings in this procedure, heed the following:



Handle the O-ring with bare hands. Never wear gloves.
 
Lubricate the O-ring with new engine oil.
 
Do not clean the O-ring with solvent.
 
Make sure that the O-ring and its mating part are free of foreign material.
 
When installing the O-ring, be careful not to scratch it with a tool or fingernails.
 
Be careful not to twist or stretch the O-ring. If the O-ring was stretched while it was being attached, do not insert it quickly into the fuel tube.
 
Insert the O-ring straight into the fuel tube. Do not de-center or twist it.
 

  1. Install the fuel damper and fuel sub-tube.
  2.  
  3. Insert the fuel damper and fuel sub-tube straight into the fuel tube.
  4.  
  5. Tighten the mounting bolts evenly in turn.
  6.  
  7. After tightening the mounting bolts, make sure that there is no gap between the flange and fuel tube.
  8.  
  9. Install O-rings onto fuel injector. The upper and lower O-ring are different. Be careful not to confuse them. The O-rings are identified as follows:

    Fuel tube side O-ring: Blue
     
    Nozzle side O-ring: Brown
     

  10.  
  11. Install each fuel injector onto the fuel tube, as follows:
    1. Insert the clip into the clip mounting groove on the fuel injector.
    2.  
    3. Insert the clip so that lug A of the fuel injector matches notch A of the clip.
      CAUTION
      Do not reuse old clips. Replace them with new ones. Be careful to keep the clip from interfering with the O-ring. If interference occurs, replace the O-ring with a new one.

    4.  
    5. Insert the fuel injector into the fuel tube, matching it to the axial center, with the clip attached. Insert the fuel injector so that lug B of fuel tube matches notch B of the clip. Make sure that the fuel tube flange is securely fixed in the groove on the clip.
    6.  
    7. Make sure that installation is complete by checking that the fuel injector does not rotate or come off.
    8.  

  12.  
  13. Install the fuel tube and fuel injector assembly onto the intake manifold, and tighten the mounting bolts in two steps as shown.
    CAUTION
    Be careful not to let the tips of the injector nozzles come into contact with other parts.



    1st Step: 7 ft. lbs. (10 Nm)
     
    2nd Step: 17 ft. lbs. (24 Nm)
     

  14.  
  15. Connect the injector sub-wiring harness.
  16.  
  17. Install the upper and lower intake manifold collectors.
  18.  
  19. Install the fuel sub-tube on the rear end of the lower intake manifold collector.
  20.  
  21. Connect the fuel feed hose and damper. After tightening the mounting bolts, make sure that there is no gap between the flange and the fuel sub-tube.
  22.  
  23. Connect the quick connector between the fuel feed hose and centralized under-floor piping connection with the following procedure:
    1. Check the connection for damage and foreign materials.
    2.  
    3. Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
    4.  
    5. After connecting the quick connector, visually confirm that the two retainer tabs are connected to connector, then pull the tube and connector to make sure they are securely connected.
    6.  
    7. Install quick connector cap to quick connector connection.
    8.  
    9. Install the quick connector cap with the arrow on the surface facing in the direction of the quick connector (fuel feed hose side).
      CAUTION
      If the cap cannot be installed smoothly, the quick connector may not have been installed correctly. Check the connection again.

    10.  
    11. Secure the fuel feed hose to the clamp.
    12.  

  24.  
  25. The remainder of installation is the reverse of removal.
  26.  
  27. Perform the following once installation is complete:


  28.  
  29. After installing the fuel tubes, make sure there is no fuel leakage at the connections in the following steps:
    1. Apply fuel pressure to the fuel lines by turning the ignition switch ON (with the engine stopped). Then check for fuel leaks at all connections.
    2.  
    3. Start the engine and while holding it at a high rpm check for fuel leaks at all connections.
      NOTE
      Use mirrors to check hard-to-see connections.

    4.  

  30.  

4.5L Engine


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Fig. Exploded view of fuel rail and injector mounting and related components-4.5L engine



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Fig. Quick connector release tool used to disconnect the fuel line quick connector-4.5L engine



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Fig. Fuel rail mounting bolt tightening sequence-4.5L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Do not remove or disassemble parts unless instructed as shown in the figure.

  2.  
  3. Remove the engine cover.
  4.  
  5. Release fuel pressure.
  6.  
  7. Disconnect the fuel feed hose on the engine side, as follows:
    NOTE
    Except to confirm whether or not there is a quick connector cap, perform the same procedure for the side of centralized under-floor piping as well.

    1. Remove the quick connector cap from the quick connector connection (engine side only).
      CAUTION
      Disconnect the quick connector by using quick connector release tool SST: J-45488 or equivalent; not by picking out the retainer tabs. Inserting the quick connector release tool too hard will not disconnect the quick connector. Hold quick connector release where it contacts and goes no further. Do not pull with lateral force applied. O-ring inside quick connector may be damaged.

    2.  
    3. Disconnect the quick connector from the fuel feed damper. With the sleeve side of the quick connector release tool facing the quick connector, install the quick connector release tool onto the fuel tube. Insert the quick connector release tool into the quick connector until the sleeve contacts and goes no further. Hold the quick connector release tool in that position. Draw and pull out the quick connector, holding position A, straight from the fuel damper.
      CAUTION
      Heed the following when working with the fuel system tubing:



      Prepare a container and cloth beforehand since fuel will leak out.
       
      Avoid fire and sparks.
       
      Keep parts away from a heat source. Especially, be careful when welding is performed around them.
       
      Do not expose parts to battery electrolyte or other acids.
       
      Do not bend or twist the connection between the quick connector and the fuel feed hose during installation/removal.
       
      To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
       

    4.  

  8.  
  9. Disconnect the fuel damper and fuel hose assembly from the left-hand and right-hand fuel tubes.
    CAUTION
    While the hoses are disconnected, plug them to prevent fuel from leaking and do not separate the fuel damper and fuel hose.

  10.  
  11. Remove the upper intake manifold.
  12.  
  13. Disconnect the wiring harness connector from the fuel injector.
  14.  
  15. Loosen the mounting bolts in reverse order shown, and remove the fuel tube and fuel injector assembly.
    CAUTION
    Do not tilt the fuel injector assembly, or remaining fuel in the pipes may flow out from the pipes.

  16.  
  17. Remove the spacers on the lower intake manifold.
  18.  
  19. Remove the fuel injector from the fuel tube, as follows:
    1. Open and remove the clip.
    2.  
    3. Remove the fuel injector from the fuel tube by pulling it straight out.
    4.  
    5. During injector removal, heed the following items:

      Be careful with the remaining fuel that leaks from the fuel tube.
       
      Be careful not to damage the injector nozzles during removal.
       
      Do not bump or drop the fuel injectors.
       
      Do not disassemble the fuel injectors.
       

    6.  

  20.  
  21. Remove the right-hand fuel damper and fuel feed damper.
  22.  

To install:


CAUTION
When handling all O-rings in this procedure, heed the following:



Handle the O-ring with bare hands. Never wear gloves.
 
Lubricate the O-ring with new engine oil.
 
Do not clean the O-ring with solvent.
 
Make sure that the O-ring and its mating part are free of foreign material.
 
When installing the O-ring, be careful not to scratch it with a tool or fingernails.
 
Be careful not to twist or stretch the O-ring. If the O-ring was stretched while it was being attached, do not insert it quickly into the fuel tube.
 
Insert the O-ring straight into the fuel tube. Do not de-center or twist it.
 

  1. Install the right-hand fuel damper and fuel feed damper, as follows:
    1. Insert the right-hand fuel damper and fuel feed damper straight into the right-hand fuel tube.
    2.  
    3. Tighten the mounting bolts evenly in turn.
    4.  
    5. After tightening the mounting bolts, make sure that there is no gap between the flange and the right-hand fuel tube.
    6.  

  2.  
  3. Install new O-rings on the fuel injector, paying attention to the fact that the upper and lower O-rings are different. Be careful not to confuse them. The fuel tube side O-ring is black, whereas the nozzle side O-ring is green.
  4.  
  5. Install the fuel injector onto the fuel tube, as follows:
    1. Insert the clip into clip mounting groove on the fuel injector. Insert the clip so that lug A of the fuel injector matches notch A of the clip. Do not reuse clips; replace them with new ones.
      NOTE
      Be careful to keep the clip from interfering with the O-ring. If interference occurs, replace the O-ring with a new one.

    2.  
    3. Insert the fuel injector into the fuel tube with the clip attached. Insert the fuel injector while matching it to the axial center. Insert the fuel injector so that lug B of the fuel tube matches notch B of the clip. Make sure that the fuel tube flange is securely fixed in the flange fixing groove on the clip.
    4.  
    5. Make sure that installation is complete by checking that the fuel injector does not rotate or come off. Make sure that the protrusions of the fuel injectors are aligned with the cutouts of the clips after installation.
    6.  

  6.  
  7. Install spacers on the lower intake manifold.
  8.  
  9. Install the fuel tube and fuel injector assembly onto the intake manifold.
    CAUTION
    Be careful not to let the tip of the injector nozzle come in contact with other parts.

  10.  
  11. Tighten the mounting bolts in two steps, in numerical order shown:

    1st Step: 7 ft. lbs. (10 Nm)
     
    2nd Step: 17 ft. lbs. (23.5 Nm)
     

  12.  
  13. Connect the fuel feed hose on the engine side, as follows
    1. Make sure no foreign substances are deposited in and around the fuel tube and quick connector, and that they are not damaged.
    2.  
    3. Thinly apply new engine oil around the fuel tube from the tip end to the spool end.
    4.  
    5. Align the center to insert the quick connector straight into the fuel tube.
      CAUTION
      Carefully align the center to avoid off-center or crooked insertion to prevent damage to the O-ring inside the quick connector.

    6.  
    7. Insert the fuel tube into the quick connector until the top spool is completely inside the quick connector, and the 2nd level spool exposes right below the quick connector. Hold position A when inserting fuel tube into the quick connector. Insert until you hear a click sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
    8.  
    9. Pull the quick connector by hand holding position A. Make sure it is completely engaged (connected) so that it does not disconnect from fuel tube.
    10.  
    11. Install the quick connector cap on quick connector connection. (on the engine side only).
    12.  
    13. Install the fuel feed hose to the hose clamps.
    14.  

  14.  
  15. Perform the preceding step and associated sub steps for the side of the centralized under-floor piping as well.
  16.  
  17. The remainder of installation is the reverse of removal.
  18.  
  19. Once installation is complete, turn the ignition switch ON (with the engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at all connection points.
    NOTE
    Use mirrors for checking fuel connections that are hard to see.

  20.  
  21. Start the engine. With engine speed increased, check again for fuel leakage at all connection points.
  22.  

 
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