Nissan Sentra/Pulsar/NX 1982-1996 Repair Guide

Fuel Injectors

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11



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Fig. Fig. 1: Disconnect the fuel pressure and return hoses, from the fuel rail. Use a rag to catch spillage



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Fig. Fig. 2: Detach the fuel injector electrical connectors



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Fig. Fig. 3: Remove the fuel rail retaining bolts



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Fig. Fig. 4: Remove the fuel rail and fuel injectors as an assembly



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Fig. Fig. 5: Be careful, so not to lose the two fuel rail spacers during removal and installation



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Fig. Fig. 6: Replace the insulators whenever the fuel rail has been removed



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Fig. Fig. 7: Once the fuel rail has been removed, the fuel injector cover screws can be removed



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Fig. Fig. 8: Although it is not recommended, individual injectors can be removed with the rail assembly intact



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Fig. Fig. 9: Before installing the injector cover, make certain that the injector is properly aligned



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Fig. Fig. 10: Use a pick type tool to remove and install the fuel injector upper O-ring



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Fig. Fig. 11: Use a pick type tool to remove and install the fuel injector lower O-ring


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Also observe all safety practices outlined previously in the Fuel System Safety Precautions. Failure to do so may result in fire or personal injury.

E15ET Turbo Engine

See Figures 12, 13 and 14



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Fig. Fig. 12: Exploded view of fuel injector assembly-E15ET engine shown; CA16DE and CA18DE engines similar



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Fig. Fig. 13: Remove the fuel injector from the fuel rail as shown-E15ET, CA16DE and CA18DE engines



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Fig. Fig. 14: Fuel rail connection points-E15ET engine

  1. Following proper procedures, relieve fuel system residual pressure.
  2.  
  3. Remove the air inlet pipe and the hose.
  4.  
  5. Disconnect the accelerator wire and (if equipped with an automatic transaxle) the throttle wire.
  6.  
  7. Disconnect the throttle valve switch electrical harness connector, the mounting bolts and the throttle chamber.
  8.  
  9. Remove the PCV valve and the hose.
  10.  
  11. Loosen the clamps at both ends of the air pipe.
  12.  
  13. Disconnect the IVC and the air regulator harness connectors.
  14.  
  15. Remove the air pipe.
  16.  
  17. Disconnect the harness connectors from the injectors. Remove the fuel hoses. Remove the fuel rail mounting bolts and the fuel injector mounting screws.
  18.  
  19. Remove the fuel rail assembly by pulling out the fuel rail and the injectors.
  20.  
  21. Unfasten the fuel injector-to-fuel rail hose clamp and pull the injector from the fuel rail.
  22.  


WARNING
The following procedure must be followed carefully. Use extreme care when using heat around fuel system components. DO NOT allow the soldering iron to cut through the hose; cut only the braided reinforcement, from the hose.

  1. Remove the injectors from the rail as follows:
    1. Heat a 150 watt soldering iron.
    2.  
    3. Cut (melt) a line in the braided reinforcement, starting at the injector socket, extending 19mm (long) up the hose.
    4.  

  2.  

Be careful not to damage the socket plastic connector with the soldering iron.

  1. Pull the rubber hose off by hand.
  2.  

To install:
  1. 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.
  2.  
  3. Install injectors on fuel rail.
  4.  
  5. Install fuel rail to engine. Always use new O-rings on injectors.
  6.  
  7. Install fuel lines to fuel rail and electrical connections to injectors.
  8.  
  9. Install the air pipe.
  10.  
  11. Reconnect the IVC and the air regulator harness connectors.
  12.  
  13. Install PCV valve and hose.
  14.  
  15. Install the throttle chamber and attaching parts.
  16.  
  17. Install the air inlet pipe and hose.
  18.  
  19. Start engine and check for fuel leaks.
  20.  

CA16DE and CA18DE Engines

See Figures 15 and 16



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Fig. Fig. 15: Remove the fuel rail from the engine as shown-CA16DE and CA18DE engines



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Fig. Fig. 16: When reinstalling the fuel injectors, align the tabs as shown-CA16DE and CA18DE engines

  1. Release the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the throttle chamber, intake manifold stay, IAA unit and intake side rocker cover.
  4.  
  5. Disconnect all fuel and vacuum hoses and electrical harnesses from the pressure regulator and fuel rail (charging assembly).
  6.  
  7. Remove the injector retaining bolts and remove the injector/fuel rail assembly.
  8.  


WARNING
The following procedure must be followed carefully. Use extreme care when using heat around fuel system components. DO NOT allow the soldering iron to cut through the hose; cut only the braided reinforcement, from the hose.

  1. Remove the injectors from the rail as follows:
    1. Heat a 150 watt soldering iron.
    2.  
    3. Cut (melt) a line in the braided reinforcement, starting at the injector socket, extending 19mm (long) up the hose.
    4.  

  2.  

Be careful not to damage the socket plastic connector with the soldering iron.

  1. Pull the rubber hose off by hand.
  2.  

To install:
  1. Wet the new injector hose with clean fuel and push the rubber hose onto the injector tail piece by hand as far as it will go.
  2.  
  3. Install the injector/fuel rail assembly and torque the injector retaining bolts to 35 inch lbs. (4.0 Nm).
  4.  
  5. Reconnect all fuel and vacuum hoses and electrical harnesses.
  6.  
  7. Install the remaining components.
  8.  
  9. Connect the battery cable, start the engine and check for leaks before road testing.
  10.  

GA16DE Engine

See Figures 17, 18, 19, 20 and 21



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Fig. Fig. 17: Fuel rail bolt loosening sequence-1991-94 GA16DE engine



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Fig. Fig. 18: Exploded view of fuel rail assembly-all GA16DE engines



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Fig. Fig. 19: Fuel rail bolt tightening sequence-1991-94 GA16DE engine



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Fig. Fig. 20: Fuel rail bolt loosening sequence-1995-96 GA16DE engine



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Fig. Fig. 21: Fuel rail bolt tightening sequence-1995-96 GA16DE engine

  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Disconnect the fuel injector wiring harness connectors and the vacuum line from the fuel pressure regulator.
  4.  
  5. Disconnect the electrical connectors from each injector.
  6.  
  7. Disconnect the vacuum hose from the fuel pressure regulator.
  8.  
  9. Disconnect the fuel pressure and return lines from the fuel rail.
  10.  
  11. Remove the bolts that secure the fuel rail to the intake, in proper sequence.
  12.  
  13. Remove the injectors with the fuel rail assembly.
  14.  
  15. Remove the individual injector by removing the two bolts that secure the cap to the injector.
  16.  
  17. Remove the injector from the fuel rail by pushing the injector from the bottom and discard the O-rings.
  18.  


WARNING
DO NOT remove the injector by pulling on the electrical connector housing.

To install:
  1. Install new O-rings onto the injectors and coat the O-rings with a light coating non-silicone based oil.
  2.  
  3. Install the injector into the fuel rail assembly and install the cap that secures the injector. Tighten the cap bolts to 26-33 inch lbs. (2.9-3.8 Nm).
  4.  
  5. Install the insulators, injectors, and the fuel rail assembly to the intake manifold. Torque the retaining bolts in sequence and in two (2) steps. Torque the bolts to 12-15 ft. lbs. (16-21 Nm).
  6.  
  7. Connect the fuel lines to the fuel rail, using new clamps.
  8.  
  9. Connect the fuel injector wiring harness connectors and the vacuum line to the fuel pressure regulator.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and check for fuel leaks after the installation is complete.
  14.  

SR20DE Engine

See Figures 22, 23, 24 and 25



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Fig. Fig. 22: Fuel rail retaining bolt locations-SR20DE engine



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Fig. Fig. 23: Fuel rail component identification-SR20DE engine



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Fig. Fig. 24: Exploded view of the fuel injector assembly-SR20DE engine



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Fig. Fig. 25: Fuel rail retaining bolt tightening sequence-SR20DE engine

  1. Release the fuel system residual pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the intake manifold plenum (collector) assembly, follow the procedures outlined in Engine & Engine Overhaul .
  6.  
  7. Disconnect the vacuum hose from the pressure regulator.
  8.  
  9. Disconnect the fuel pressure and return lines from the fuel rail.
  10.  
  11. Disconnect the electrical connectors from each injector.
  12.  
  13. Remove the three bolts that secure the fuel rail to the intake, in proper sequence.
  14.  
  15. Remove the injector/fuel rail assembly.
  16.  
  17. Remove the individual injector by removing the two bolts that secure the cap to the injector.
  18.  
  19. Push out the injector from the bottom of the fuel rail assembly.
  20.  


WARNING
DO NOT remove the injector by pulling on the electrical connector housing.

To install:
  1. Install new O-rings onto the injectors and coat the O-rings with a light coating non-silicone based oil.
  2.  
  3. Install the injectors to the fuel rail and tighten the cap that secures the injector to 26-33 inch lbs. (2.9-3.8 Nm). Install the rail onto intake manifold.
  4.  
  5. Torque the fuel rail bolts as follows:
    1. Tighten all bolts in sequence to 96 inch lbs. (11 Nm).
    2.  
    3. Tighten all bolts in sequence to 15-20 ft. lbs. (21-26 Nm).
    4.  

  6.  
  7. Connect the fuel hoses to the fuel rail, using new clamps.
  8.  
  9. Connect the vacuum line to the fuel pressure regulator.
  10.  
  11. Connect the injector wiring harness.
  12.  
  13. Connect the battery cable, start the engine, and check for leaks before road testing.
  14.  

TESTING



Refer to Emission Controls for all electronic fuel injection testing and diagnostics.

 
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