Nissan Pathfinder 1996-05

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3.3L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Accelerator cable
     
    Cruise control cable
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor and switch connectors
     
    Ignition coil and power transistor connectors
     
    Exhaust Gas Recirculation (EGR) Solenoid valve connector
     
    EGR temperature sensor connector
     
    Radiator hoses
     
    Heater hoses
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Evaporative Emissions (EVAP) canister vacuum and purge hoses
     
    Brake booster vacuum hose
     
    Fuel pressure regulator vacuum hose
     
    EGR tube
     
    Left bank injector connectors
     
    Thermal transmitter
     
    Upper intake manifold ground cable
     
    Breather pipe
     
    Upper intake manifold
     
    Fuel lines
     
    Right bank injector connectors
     
    Fuel supply manifold with the injectors attached
     
    Fuel injector caps
     
    Fuel injectors
     

  8.  

To install:


NOTE
Use new insulators and O-ring seals for assembly.

  1. Install or connect the following:

    Fuel injectors
     
    Fuel injector caps. Tighten the screws to 26-34 inch lbs. (3-4 Nm).
     
    Fuel supply manifold with the injectors attached. Tighten the bolts to 96-132 inch lbs. (11-15 Nm).
     
    Right bank injector connectors
     
    Fuel lines
     
    Upper intake manifold
     
    Breather pipe
     
    Upper intake manifold ground cable
     
    Thermal transmitter
     
    Left bank injector connectors
     
    EGR tube
     
    Fuel pressure regulator vacuum hose
     
    Brake booster vacuum hose
     
    EVAP canister vacuum and purge hoses
     
    PCV valve and hose
     
    Heater hoses
     
    Radiator hoses
     
    EGR temperature sensor connector
     
    EGR Solenoid valve connector
     
    Ignition coil and power transistor connectors
     
    TP sensor and switch connectors
     
    IAC valve connector
     
    Cruise control cable
     
    Accelerator cable
     
    Air intake duct
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.5L & 4.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Release fuel pressure to zero.
  4.  
  5. Remove the intake manifold collector.
  6.  
  7. Remove the fuel tube assemblies in numerical sequence as shown in the figure at left.
  8.  
  9. Expand and remove clips securing fuel injectors.
  10.  
  11. Extract fuel injectors straight from fuel tubes.
    NOTE
    Be careful not to damage injector nozzles during removal. Do not bump or drop fuel injectors.

  12.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the fuel injector installation



Click image to see an enlarged view

Fig. Fuel rail torque sequence

  1. Carefully install O-rings, including the one used with the pressure regulator. Lubricate O-rings with a smear of engine oil.
    NOTE
    Be careful not to damage O-rings with service tools, finger nails or clips. Do not expand or twist O-rings. Discard old clips; replace with new ones.

  2.  
  3. Position clips in grooves on fuel injectors. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
  4.  
  5. Align protrusions of fuel tubes with those of fuel injectors. Insert fuel injectors straight into fuel tubes.
  6.  
  7. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with those of fuel injectors, and that flanges of fuel tubes are engaged with clips.
  8.  
  9. Tighten fuel tube assembly mounting nuts in sequence in two stages:
    1. Step 1: 84-96 inch lbs.
    2.  
    3. Step 2: 16-19 ft. lbs.
    4.  

  10.  
  11. Install all parts removed in reverse order of removal.
  12.  
  13. Turn the ignition to the ON , but do not start, to check for leaks.
  14.  

 
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