Isuzu_Rodeo_Rodeo_Sport_1997-2004

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector harness connectors
     
    Pressure regulator vacuum line
     
    Fuel lines
     
    Fuel supply manifold with injectors attached
     
    Fuel injector retaining clips
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors. Use new O-ring seals.
     
    Fuel injector retaining clips
     
    Fuel supply manifold with injectors attached. Tighten the fasteners to 14 ft. lbs. (19 Nm).
     
    Fuel lines
     
    Pressure regulator vacuum line
     
    Fuel injector harness connectors
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Fuel injector wiring connectors
     
    Fuel lines
     
    Fuel supply manifold with injectors attached
     
    Fuel injector retaining clips
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors. Use new O-ring seals.
     
    Fuel injector retaining clips
     
    Fuel supply manifold with injectors attached. Tighten the bolts to 60 inch lbs. (6.5 Nm).
     
    Fuel lines
     
    Fuel injector wiring connectors
     
    Engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

3.5L VIN Y Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Disconnect the battery ground.

    Click image to see an enlarged view

    Fig. Fuel rail and injectors-3.5L VIN Y engine

  6.  
  7. Remove the intake manifold.
  8.  
  9. Disconnect the fuel supply line.
  10.  
  11. Remove the joint pipe.
  12.  
  13. Remove the bolts and the fuel rail.
  14.  
  15. Remove the O-ring and back-up ring from the injectors.

    Click image to see an enlarged view

    Fig. Injector installed in head-3.5L VIN Y engine

  16.  
  17. Remove the spring clip and remove each injector with a slidehammer.

    Click image to see an enlarged view

    Fig. Injector removal-3.5L VIN Y engine

  18.  
  19. Use needle-nose pliers to pull and cut the TIP seal from each injector. Take care to avoid damage to the injector.
  20.  

To install:

  1. Install a new TIP seal with tool J46911:
    1. Place the new seal on the tool.
    2.  
    3. Align the thick end of the tool with the injector nozzle.
    4.  
    5. Use the pusher to install the seal.

      Click image to see an enlarged view

      Fig. Install a new TIP seal-3.5L VIN Y engine

    6.  
    7. Pull the tool from the injector.
    8.  
    9. Use the resizing tool to twist and shape the seal to the proper taper.

      Click image to see an enlarged view

      Fig. Size the new seal-3.5L VIN Y engine

    10.  
    11. Clean and debris from the seal and apply clean engine oil.
    12.  

  2.  
  3. Install new O-rings and back-up rings on the injectors.
  4.  
  5. Clean the injector bores thoroughly.
  6.  
  7. Install new spring clips and install the injectors.
  8.  
  9. The remainder of installation is the reverse of removal. Torque the fuel rail bolts to 18 ft. lbs. (25 Nm). Torque the fuel lines connections to 84 inch lbs. (10 Nm).
  10.  

 
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