Land Rover 2000-05

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Remove intake manifold chamber.
  6.  
  7. Remove underbelly panel.
  8.  
  9. Using a 3 / 8 in. socket bar raise auxiliary drive belt tensioner and release drive belt from alternator and PAS pump pulleys.
  10.  
  11. Remove nuts and bolts securing alternator.
  12.  
  13. Release alternator and place aside.
  14.  
  15. Note position of coil ground lead, remove 3 nuts and 3 bolts securing ignition coils to left side intake manifold.
  16.  
  17. Remove ignition coils ground. Release and position coil aside.
  18.  
  19. Disconnect clips securing right side injector harness to injector protection cover, or to bosses on fuel rail.
  20.  
  21. Remove 2 bolts securing right side fuel rail to right side intake manifold.
  22.  
  23. Release clips and disconnect injector connectors.
  24.  
  25. Remove 2 bolts securing fuel rail to left side intake manifold.
  26.  
  27. Release clips and disconnect injector connectors.
  28.  
  29. Release injectors from manifolds, raise fuel rail assembly, disconnect 4 clips securing injector harness to fuel rails and move harness aside.
  30.  
  31. Remove fuel rail and discard O-rings.
    CAUTION
    Always fit plugs to open connections to prevent contamination.

  32.  
  33. Remove clip securing injector to fuel rail.
  34.  
  35. Remove injector from fuel rail, remove and discard O-ring from injector.
    CAUTION
    Always fit plugs to open connections to prevent contamination.

  36.  

To install:

  1. Clean injector and mating face in fuel rail.
  2.  
  3. Remove cap from new injector and fit to old injector.
  4.  
  5. Lubricate new O-ring with castor oil and fit to injector.
  6.  
  7. Install injector to fuel rail and secure with clip.
  8.  
  9. Lubricate new O-rings with castor oil and fit to injectors.
  10.  
  11. Remove plugs from intake manifolds.
  12.  
  13. Position injector harness to fuel rail and secure with clips.
  14.  
  15. Position injectors and fuel rail to intake manifolds.
  16.  
  17. Connect connectors to injectors.
  18.  
  19. Install and tighten 4 bolts securing fuel rail to intake manifold to 7 ft. lbs. (9 Nm).
  20.  
  21. Position ignition coils to left side intake manifold.
  22.  
  23. Position ground lead, fit nuts and bolts securing ignition coils to left side intake manifold and tighten to 7 ft. lbs. (9 Nm).
  24.  
  25. Position alternator and secure with nuts and bolts, tighten to 45 Nm (33 ft. lbs.).
  26.  
  27. Using a 3 / 8 square drive socket bar, raise auxiliary drive belt tensioner and fit drive belt to pulleys.
  28.  
  29. Install underbelly panel.
  30.  
  31. Install intake manifold chamber.
  32.  
  33. Connect the negative battery cable.
  34.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    It may be necessary to pry on the housing to break the seal. If so, use a small block of wood as a pry point between the manifold and ram housing. NEVER pry on the fuel rail!


    NOTE
    Advanced EVAPS vehicles have a threaded connector.



    Battery ground cable
     
    Fuel system pressure
     
    Throttle cable
     
    Cruise control cable
     
    Harness clip from the throttle linkage bracket
     
    Breather hose form the plenum
     
    IAC connector
     
    TPS connector
     
    Plenum chamber
     
    Purge hose
     
    Crankcase breather hose
     
    Pressure regulator vacuum hose
     
    Ram housing from the intake manifold
     



    The 8 injector plugs
     
    Fuel temperature sensor connection
     
    Fuel feed hose form the fuel rail
     
    Fuel return hose from the pressure regulator
     



    Fuel rail and ignition coil bracket from the manifold
     
    Coil bracket
     
    Fuel rail and injectors
     
    Injector retaining clips and injectors
     
    Two O-rings from each injector
     

  4.  

To install:

  1. Install or connect the following:

    New O-rings coated with silicone grease
     
    Injectors and clips on the rail
     
    Fuel rail and injectors on the manifold
     
    Ignition coil and bracket
     
    Return hose
     
    Fuel feed line. Torque the union to 12 ft. lbs. (16 Nm).
     
    All injector wiring
     
    Ram housing. Use Loctite 577, or equivalent, as a sealant. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    All vacuum hoses
     
    All remaining wiring
     
    Plenum chamber. Use Loctite 577, or equivalent, as a sealant. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Coolant hoses
     
    All remaining hoses and wires
     
    Battery ground
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove upper intake manifold.
  4.  
  5. Carefully maneuver ignition coil assembly from between intake manifold and bulkhead.
  6.  
  7. Position absorbent cloth beneath fuel pipe to catch spillage.
  8.  
  9. Disconnect fuel feed hose from fuel rail.
  10.  
  11. Release injector harness from fuel rail and disconnect injector connectors.
  12.  
  13. Remove 4 bolts securing fuel rail to lower intake manifold.
  14.  
  15. Release injectors from intake manifold and remove fuel rail and injectors.
    CAUTION
    Always plug all openings immediately to prevent contamination.

  16.  
  17. Remove and discard 2 O-rings from each injector.
  18.  
  19. Fit protective caps to each engine of injectors.
  20.  

To install:

  1. Clean injectors and recesses in fuel rail and intake manifold.
  2.  
  3. Lubricate new O-rings with silicone grease and fit to each end of injectors.
  4.  
  5. Fit injectors to fuel rail and secure with spring clips.
  6.  
  7. Position fuel rail assembly and push-fit each injector into intake manifold.
  8.  
  9. Position bolts securing fuel rail to intake manifold and tighten bolts to 7 ft. lbs. (9 Nm).
  10.  
  11. Connect fuel feed hose to fuel rail.
  12.  
  13. Connect injector harness connectors and secure to fuel rail.
  14.  
  15. Carefully position ignition coil assembly between lower intake manifold and bulkhead.
  16.  
  17. Install upper intake manifold.
  18.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air intake hose.
  8.  
  9. Remove both ignition coil covers.
  10.  
  11. Disconnect all ignition coil connectors.
  12.  
  13. Disconnect and label all intake manifold electrical connectors.
  14.  
  15. Remove 2 nuts attaching fuel injector harness to fuel rail.
  16.  
  17. On the left side, remove vacuum reservoir and mounting bracket and fuel hose and mounting bracket.
  18.  
  19. Disconnect left side fuel injector connectors.
  20.  
  21. Disconnect main engine harness and move aside.
  22.  
  23. Remove the secondary air solenoid valve from the right side.
  24.  
  25. Disconnect right side fuel injector connectors.
  26.  
  27. Position the fuel injector harness aside.
  28.  
  29. Remove the air intake plenum.
  30.  
  31. Disconnect the fuel feed line from the fuel rail.
  32.  
  33. Disconnect air injection vacuum hose.
  34.  
  35. Remove 4 bolts attaching engine cover brackets to intake manifold.
  36.  
  37. Remove bolt attaching fuel rail to intake manifold, and remove fuel rail with injectors.
  38.  

To install:

  1. Clean injectors and recesses in fuel rail and intake manifold.
  2.  
  3. Lubricate new O-rings with silicone grease and fit to each end of injectors.
  4.  
  5. Fit injectors to fuel rail and secure with spring clips.
  6.  
  7. Position fuel rail assembly and push-fit each injector into intake manifold.
  8.  
  9. Install bolt attaching fuel rail to intake manifold.
  10.  
  11. Connect air injection vacuum hose.
  12.  
  13. Connect the fuel feed line from the fuel rail.
  14.  
  15. Clean the fuel line connections.
  16.  
  17. Install the air intake plenum.
  18.  
  19. Reposition the fuel injector harness.
  20.  
  21. Connect right side fuel injector connectors.
  22.  
  23. Install the secondary air solenoid valve to the right side.
  24.  
  25. Connect the main engine harness.
  26.  
  27. Connect left side fuel injector connectors.
  28.  
  29. On the left side, install vacuum reservoir and mounting bracket and fuel hose and mounting bracket.
  30.  
  31. Connect fuel injector harness to fuel rail.
  32.  
  33. Connect all labeled intake manifold electrical connectors.
  34.  
  35. Connect all ignition coil connectors.
  36.  
  37. Install both ignition coil covers.
  38.  
  39. Connect the air intake hose.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Start the vehicle and check for leaks.
  44.  

 
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