Toyota Tercel 1984-1994 Repair Guide

Fuel Rail Assembly

Print

REMOVAL & INSTALLATION



See Figures 1 and 2


CAUTION
The fuel system is under pressure. Release pressure slowly and contain spillage. Observe "no smoking/no open flame'' precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Disconnect the negative battery cable, then relieve fuel system pressure.
  2.  
  3. Disconnect the PCV hoses.
  4.  
  5. Remove the air intake duct. Disconnect the accelerator cable.
  6.  
  7. If so equipped, disconnect the transaxle shift cable (automatic transmission) and/or the cruise control cable.
  8.  
  9. Label and unplug the vacuum hose from the pressure regulator.
  10.  
  11. Remove the dash pot and link bracket, if equipped.
  12.  
  13. Disconnect the fuel inlet and return hoses.
  14.  
  15. If equipped, remove the cold start injector.
  16.  

Not all engines are equipped with a cold start injector.

  1. Unplug the injector electrical connections. Be sure to release the locking tabs before attempting to unplug the connector.
  2.  
  3. At the fuel rail, remove the attaching bolts. Lift the delivery pipe and the injectors free of the engine. DON'T drop the injectors.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the fuel rail attaching bolts

  1. Remove the insulators and spacers from the cylinder head. Note the correct placement along with the amount of spacers and insulators used.
  2.  

To install:

Always use new O-rings and gaskets when installing fuel system components.



Click image to see an enlarged view

Fig. Fig. 2: Always use new gaskets and O-rings

  1. Install the insulators into each injector hole. Place the spacers on the fuel rail mounting holes in the cylinder head.
  2.  
  3. Position the fuel rail on the cylinder head. Install the bolts, then tighten them to 14 ft. lbs. (19 Nm).
  4.  
  5. Engage the electrical connectors to each injector. On color-coded injectors, engage the gray connectors to the dark blue injectors, then the brown connectors to the brown injectors.
  6.  
  7. If equipped, install the cold start injector with new gaskets.
  8.  
  9. Connect the fuel inlet and return hoses. Tighten to 22 ft. lbs. (29 Nm).
  10.  
  11. Install the dashpot with the link bracket, if equipped.
  12.  
  13. Connect the vacuum hose to the pressure regulator. Attach the PCV hose.
  14.  
  15. Reconnect the accelerator, transaxle control and cruise control cables, then install the air intake duct.
  16.  
  17. Connect the battery cable to the negative battery terminal. Start the engine and check for leaks.
  18.  


CAUTION
If there is a leak at any fitting, the line will be under pressure and the fuel may spray in a fine mist. This mist is extremely explosive. Shut the engine off immediately if any leakage is detected. Use rags to wrap the leaking fitting until the pressure diminishes and wipe up any fuel from the engine area.

 
label.common.footer.alt.autozoneLogo