Vibe 2003-2005

Fuel Rail (Supply Manifold) & Injectors 2

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Removal & Installation



2ZZ-GE Engine

Tools Required



J 43178 Fuel Line Disconnect Tool

Click image to see an enlarged view

Fig. Remove the four fasteners from the engine cover (1).

 

  1. Remove the four fasteners from the engine cover (1).
  2.  
  3. Remove the engine cover (1) from the engine.

    Click image to see an enlarged view

    Fig. Disconnect the coupling for the fuel feed hose from the fuel feed pipe of the fuel rail using the J 43178 .

  4.  
  5. Relieve the fuel pressure.
  6.  
  7. Remove the quick connect coupling cover.
  8.  
  9. Disconnect the coupling for the fuel feed hose from the fuel feed pipe of the fuel rail using the J 43178 . Use a shop towel in order to catch any remaining fuel that may leak.

    Click image to see an enlarged view

    Fig. Disconnect the PCV hose (1) from the PCV valve. Disconnect the PCV breather hose (2). Disconnect the EVAP hose (3).

  10.  
  11. Disconnect the PCV hose (1) from the PCV valve.
  12.  
  13. Disconnect the PCV breather hose (2).
  14.  
  15. Disconnect the EVAP hose (3).
  16.  
  17. Swing the two PCV hoses and the EVAP hose away from the cylinder head
  18.  
  19. Remove the bolt to the ignition coil wire harness bracket.
  20.  
  21. Disconnect the electrical connectors to the four fuel injectors.

    Click image to see an enlarged view

    Fig. Remove the fastener (1) from the fuel supply pipe bracket. Remove the two fasteners (4) from the fuel rail (3). Remove the fuel rail (3) and the spacers (2) from the engine.

  22.  
  23. Remove the fastener (1) from the fuel supply pipe bracket.
  24.  
  25. Remove the two fasteners (4) from the fuel rail (3).
  26.  
  27. Remove the fuel rail (3) and the spacers (2) from the engine.
  28.  
  29. Remove the fuel injector with the O-rings and with the grommets from the fuel rail.
  30.  

To install:

Click image to see an enlarged view

Fig. Install new O-rings (3) and new grommets (2) on the fuel injectors (1). Apply clean engine oil to the O-rings (3) and to the grommets (2).

  1. Install new O-rings (3) and new grommets (2) on the fuel injectors (1).
  2.  
  3. Apply clean engine oil to the O-rings (3) and to the grommets (2).
  4.  
  5. Install the fuel injectors (1) into the fuel rail.

    Click image to see an enlarged view

    Fig. Install the fuel rail (3) and the spacers (2) onto the engine. Secure the fuel rail to the engine with the 2 fasteners (4).

  6.  
  7. Install the fuel rail (3) and the spacers (2) onto the engine.
  8.  
  9. Secure the fuel rail to the engine with the 2 fasteners (4). Tighten the fasteners to 21 ft. lbs. (29 Nm).
  10.  
  11. Install the fastener (1) to the fuel supply pipe bracket. Tighten the fastener to 80 inch lbs (9 Nm).
  12.  
  13. Connect the electrical connectors to the four fuel injectors.
  14.  
  15. Install the bolt to the ignition coil wire harness bracket. Tighten the fastener to 89 inch lbs (10 Nm).

    Click image to see an enlarged view

    Fig. Connect the EVAP hose (3), the PCV breather hose (2) and the PCV hose (1) to the PCV valve.

  16.  
  17. Connect the EVAP hose (3).
  18.  
  19. Connect the PCV breather hose (2).
  20.  
  21. Connect the PCV hose (1) to the PCV valve.

    Click image to see an enlarged view

    Fig. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail.

  22.  
  23. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail.
  24.  
  25. Install the quick connect coupling cover.
  26.  
  27. Connect the negative battery cable. Tighten the retainer for the negative battery cable terminal to 11 ft. lbs. (15 Nm).
  28.  
  29. Turn ON the ignition in order to pressurize the fuel system.
  30.  
  31. Turn OFF the ignition.
  32.  
  33. Inspect for fuel leaks.
  34.  
  35. Repair any fuel leaks as necessary.

    Click image to see an enlarged view

    Fig. Install the engine cover (1) to the engine.

  36.  
  37. Install the engine cover (1) to the engine.
  38.  
  39. Secure the engine cover (1) with the four fasteners. Tighten the fasteners to 62 inch lbs (7 Nm).
  40.  

Tools Required



J 43178 Fuel Line Disconnect Tool

Click image to see an enlarged view

Fig. Remove the four fasteners from the engine cover (1).

 

  1. Remove the four fasteners from the engine cover (1).
  2.  
  3. Remove the engine cover (1) from the engine.

    Click image to see an enlarged view

    Fig. Disconnect the coupling for the fuel feed hose from the fuel feed pipe of the fuel rail using the J 43178 .

  4.  
  5. Relieve the fuel pressure.
  6.  
  7. Remove the quick connect coupling cover.
  8.  
  9. Disconnect the coupling for the fuel feed hose from the fuel feed pipe of the fuel rail using the J 43178 . Use a shop towel in order to catch any remaining fuel that may leak.

    Click image to see an enlarged view

    Fig. Disconnect the PCV hose (1) from the PCV valve. Disconnect the PCV breather hose (2). Disconnect the EVAP hose (3).

  10.  
  11. Disconnect the PCV hose (1) from the PCV valve.
  12.  
  13. Disconnect the PCV breather hose (2).
  14.  
  15. Disconnect the EVAP hose (3).
  16.  
  17. Swing the two PCV hoses and the EVAP hose away from the cylinder head
  18.  
  19. Remove the bolt to the ignition coil wire harness bracket.
  20.  
  21. Disconnect the electrical connectors to the four fuel injectors.

    Click image to see an enlarged view

    Fig. Remove the fastener (1) from the fuel supply pipe bracket. Remove the two fasteners (4) from the fuel rail (3). Remove the fuel rail (3) and the spacers (2) from the engine.

  22.  
  23. Remove the fastener (1) from the fuel supply pipe bracket.
  24.  
  25. Remove the two fasteners (4) from the fuel rail (3).
  26.  
  27. Remove the fuel rail (3) and the spacers (2) from the engine.
  28.  
  29. Remove the fuel injector with the O-rings and with the grommets from the fuel rail.
  30.  

To install:

Click image to see an enlarged view

Fig. Install new O-rings (3) and new grommets (2) on the fuel injectors (1). Apply clean engine oil to the O-rings (3) and to the grommets (2).

  1. Install new O-rings (3) and new grommets (2) on the fuel injectors (1).
  2.  
  3. Apply clean engine oil to the O-rings (3) and to the grommets (2).
  4.  
  5. Install the fuel injectors (1) into the fuel rail.

    Click image to see an enlarged view

    Fig. Install the fuel rail (3) and the spacers (2) onto the engine. Secure the fuel rail to the engine with the 2 fasteners (4).

  6.  
  7. Install the fuel rail (3) and the spacers (2) onto the engine.
  8.  
  9. Secure the fuel rail to the engine with the 2 fasteners (4). Tighten the fasteners to 21 ft. lbs. (29 Nm).
  10.  
  11. Install the fastener (1) to the fuel supply pipe bracket. Tighten the fastener to 80 inch lbs (9 Nm).
  12.  
  13. Connect the electrical connectors to the four fuel injectors.
  14.  
  15. Install the bolt to the ignition coil wire harness bracket. Tighten the fastener to 89 inch lbs (10 Nm).

    Click image to see an enlarged view

    Fig. Connect the EVAP hose (3), the PCV breather hose (2) and the PCV hose (1) to the PCV valve.

  16.  
  17. Connect the EVAP hose (3).
  18.  
  19. Connect the PCV breather hose (2).
  20.  
  21. Connect the PCV hose (1) to the PCV valve.

    Click image to see an enlarged view

    Fig. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail.

  22.  
  23. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail.
  24.  
  25. Install the quick connect coupling cover.
  26.  
  27. Connect the negative battery cable. Tighten the retainer for the negative battery cable terminal to 11 ft. lbs. (15 Nm).
  28.  
  29. Turn ON the ignition in order to pressurize the fuel system.
  30.  
  31. Turn OFF the ignition.
  32.  
  33. Inspect for fuel leaks.
  34.  
  35. Repair any fuel leaks as necessary.

    Click image to see an enlarged view

    Fig. Install the engine cover (1) to the engine.

  36.  
  37. Install the engine cover (1) to the engine.
  38.  
  39. Secure the engine cover (1) with the four fasteners. Tighten the fasteners to 62 inch lbs (7 Nm).
  40.  

 
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