Altima 2007-2009

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Remove the engine cover.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. On 2.5L engine, remove the front air duct.
  6.  
  7. On 3.5L engine, remove air cleaner case, mass air flow sensor and air intake tube as an assembly.
    WARNING
    Prepare a container and cloth for catching any spilled fuel. This operation should be performed in a place that is free from any open flames.



    Click image to see an enlarged view

    Fig. Fuel injector assembly-2.5L Engine



    Click image to see an enlarged view

    Fig. Fuel injector assembly-3.5L Engine

  8.  
  9. Disconnect the fuel hose quick connector at the fuel tube side. While hoses are disconnected, seal their openings with vinyl bag or similar material to prevent foreign material from entering them.

    Click image to see an enlarged view

    Fig. Use the special tool to release the fuel line quick connector.

  10.  
  11. Remove the intake manifold.
  12.  
  13. Disconnect the injector wiring harness at the front of the engine and remove it from the bracket.
  14.  
  15. Remove the bolts and remove the fuel tube and fuel injectors as an assembly.
  16.  
  17. To remove the fuel injectors from the fuel tube, release the clip and pull fuel injector straight out of the fuel tube. Be careful not to damage the nozzle.
  18.  

To install:


NOTE
When injectors are removed from the tube, the O-rings and retainer clips should be replaced.

  1. Fit new O-rings to the injector.
  2.  
  3. Fit a new clip onto the injector. Make sure the tab opposite the electrical connector fits into the notch of the clip.
  4.  
  5. Insert the fuel injector into fuel tube.

    On 2.5L engine, the flange on the tube is longer on one side; make sure it fits into the notch on the clip. When properly installed, the injector should not rotate in the tube.
     
    On 3.5L engine, make sure the tab on the tube fits into the notch on the clip. When properly installed, the injector should not rotate in the tube.
     

  6.  
  7. Install the fuel tube assembly and torque the bolts in two steps. On 3.5L engine, tighten the bolts at the connected end first.

    Step 1: 7 ft. lbs. (10 Nm)
     
    Step 2: 16 ft. lbs. (22 Nm)
     

  8.  
  9. Install the fuel tube protector bracket.
  10.  
  11. Connect the fuel hose quick connector and pressurize the fuel system to check for leaks. The pump will run for two seconds each time the ignition switch is turned ON .
  12.  
  13. Install the intake manifold.
  14.  

2.5L Engine

Specific to:

Nissan Altima 2009-2010

  1. Remove engine room cover.
  2.  
  3. Release the fuel pressure.
  4.  
  5. Remove the front air duct.
  6.  
  7. Disconnect the fuel hose quick connector at the fuel tube side.
    CAUTION
    Prepare a container and cloth for catching any spilled fuel. This operation should be performed in a place that is free from any open flames. While hoses are disconnected seal their openings with vinyl bag or similar material to prevent foreign material from entering them.

  8.  
  9. Remove the intake manifold.
  10.  
  11. Disconnect sub-harness for injector at engine front side, and remove it from bracket.
  12.  
  13. Loosen the bolts in the reverse order shown, then remove fuel tube and fuel injectors as an assembly.

    Click image to see an enlarged view

    Fig. Loosen the bolts in the reverse order shown

  14.  
  15. Remove the fuel injectors from the fuel tube.

    Click image to see an enlarged view

    Fig. Exploded view of fuel injector and fuel tube assembly

    1. Release the clip and remove the fuel injector.
    2.  
    3. Pull fuel injector straight out of the fuel tube.
      CAUTION
      Be careful not to damage the nozzle. Avoid any impact, such as dropping the fuel injector. Do not disassemble or adjust the fuel injector.

    4.  

  16.  

To install:

  1. Install new O-rings on the fuel injector, the fuel side black O-ring and the nozzle side green O-ring.
    CAUTION
    Upper and lower O-rings are different. Be careful not to confuse them. Fuel tube side: black O-ring; Nozzle side: green O-ring.


    CAUTION



    Lubricate the O-rings lightly with new engine oil.
     
    Handle O-rings with bare hands only. Do not wear gloves.
     
    Do not clean O-rings with solvent.
     
    Make sure that O-ring and its mating part are free of foreign material.
     
    Be careful not to scratch O-rings during installation.
     
    Do not twist or stretch the O-ring. If the O-ring was stretched while it is attached, do not insert it into the fuel tube immediately.
     

  2.  
  3. Install the fuel injector into the fuel tube with the following procedure:

    Click image to see an enlarged view

    Fig. Install the fuel injector into the fuel tube

    1. Do not reuse the clip, replace it with a new one.
    2.  
    3. Insert the new clip into the clip mounting groove on fuel injector.
    4.  
    5. Insert the clip so that projection of fuel injector matches notch of the clip.
    6.  
    7. Fuel tube side: black O-ring
    8.  
    9. Nozzle side: green O-ring
    10.  

  4.  
  5. Insert fuel injector into fuel tube with clip attached.
    1. Insert it while matching it to the axial center.
    2.  
    3. Insert fuel injector so that projection of fuel tube matches notch of the clip.
    4.  
    5. Make sure that fuel tube flange is securely fixed in flange fixing groove on the clip.
    6.  
    7. Make sure that installation is complete by checking that fuel injector does not rotate or come off.
    8.  

  6.  
  7. Install fuel tube assembly.
    1. Insert the tip of each fuel injector into intake manifold.
    2.  
    3. Tighten the bolts in two steps in the numerical order as shown.

      Click image to see an enlarged view

      Fig. Tighten the bolts in the order shown

    4.  
    5. Step 1: 7 ft. lbs. (10 Nm)
    6.  
    7. Step 2: 16 ft. lbs. (22 Nm)
      CAUTION
      After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.

    8.  

  8.  
  9. Install the intake manifold.
  10.  
  11. Connect the fuel hose quick connector.
  12.  
  13. Installation of the remaining components is in the reverse order of removal.
  14.  
  15. Make sure there is no fuel leakage at connections as follows:
    1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
    2.  
    3. Start the engine and rev it up and check for fuel leaks at connections.
    4.  

  16.  
  17. Perform procedures for -Throttle Valve Closed Position Learning- after finishing repairs.
  18.  
  19. If electric throttle control actuator is replaced, perform procedures for -Idle Air Volume Learning- after finishing repairs.
    WARNING
    Do not touch engine immediately after stopping as engine is extremely hot.


    NOTE
    Use mirrors for checking on connections out of the direct line of sight.

  20.  

3.5L Engine

Specific to:

Nissan Altima 2009-2010


WARNING



Put a -CAUTION: FLAMMABLE- sign in the workshop.
 
Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
 
Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
 
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
 

  1. Remove engine cover.
  2.  
  3. Release the fuel pressure.
  4.  
  5. Disconnect the battery negative terminal.
  6.  
  7. Remove front wiper arm and extension cowl top.
  8.  
  9. Remove the electric throttle control actuator bolts in the reverse order as shown and remove the electric throttle control actuator.
    CAUTION
    Handle carefully to avoid any shock to the electric throttle control actuator. Do not disassemble.



    Click image to see an enlarged view

    Fig. Remove the electric throttle control actuator bolts in the reverse order as shown

  10.  
  11. Remove intake manifold collector.
  12.  
  13. When separating fuel feed hose and fuel tube connection, disconnect quick connector as follows:
    1. Remove quick connector cap from quick connector.
    2.  
    3. Disconnect quick connector from fuel tube as follows:
      CAUTION
      Disconnect quick connector by using the quick connector release (commercial service tool: J-45488, not by picking out retainer tabs.

    4.  

  14.  
  15. With the sleeve side of quick connector release facing to quick connector, install the quick connector release onto fuel tube.
  16.  
  17. Insert the quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position.
    CAUTION
    Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.

  18.  
  19. Draw and pull out quick connector straight from fuel tube.
    CAUTION



    Never pull with lateral force applied. O-ring inside quick connector may be damaged.
     
    Prepare container and cloth beforehand as fuel will leakage out.
     
    Avoid fire and sparks.
     
    Keep parts away from heat source. Especially, be careful when welding is performed around them.
     
    Never expose parts to battery electrolyte or other acids.
     
    Never bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal.
     
    To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
     

  20.  
  21. Disconnect harness connector from fuel injector.
  22.  
  23. Loosen bolts in reverse order as shown, and remove fuel tube and fuel injector assembly.
    CAUTION
    Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.



    Click image to see an enlarged view

    Fig. Loosen bolts in reverse order as shown

  24.  
  25. Remove fuel injector from fuel tube as follows:

    Click image to see an enlarged view

    Fig. Remove fuel injector from fuel tube

    1. Open and remove clip.
    2.  
    3. Remove fuel injector from fuel tube by pulling straight.
      CAUTION



      Be careful with remaining fuel that may go out from fuel tube.
       
      Be careful not to damage injector nozzle during removal.
       
      Never bump or drop fuel injector.
       
      Never disassemble fuel injector.
       

    4.  

  26.  
  27. Remove fuel damper from fuel tube.
  28.  

To install:

  1. Install fuel damper as follows:

    Click image to see an enlarged view

    Fig. Install fuel damper

    1. Install new O-ring to fuel tube as shown. When handling new O-ring, be careful of the following caution:
      CAUTION



      Handle O-ring with bare hands. Never wear gloves.
       
      Lubricate O-ring with new engine oil.
       
      Never clean O-ring with solvent.
       
      Check that O-ring and its mating part are free of foreign material.
       
      When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube.
       
      Insert new O-ring straight into fuel tube. Never twist it.
       

    2.  
    3. Install spacer to fuel damper.
    4.  
    5. Insert fuel damper straight into fuel tube.
      CAUTION



      Insert straight, checking that the axis is lined up.
       
      Never pressure-fit with excessive force.
       
      Insert fuel damper until it is touching the fuel tube.
       

    6.  
    7. Tighten bolts evenly in turn.
    8.  
    9. After tightening bolts, check that there is no gap between fuel damper cap and fuel tube.
    10.  

  2.  
  3. Install new O-rings to fuel injector paying attention to the following.
    CAUTION



    Upper and lower O-ring are different. Be careful not to confuse them.
     
    Fuel tube side: Black
     
    Nozzle side: Green
     
    Lubricate O-ring with new engine oil.
     
    Never clean O-ring with solvent.
     
    Check that O-ring and its mating part are free of foreign material.
     
    When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube.
     
    Insert O-ring straight into fuel injector. Never decenter or twist it.
     

  4.  
  5. Install fuel injector to fuel tube as follows:

    Click image to see an enlarged view

    Fig. Install fuel injector to fuel tube

    1. Insert clip into clip groove on fuel injector.
    2.  
    3. Insert clip so that protrusion of fuel injector matches cutout of clip.
      CAUTION
      Never reuse clip. Replace it with new one. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.

    4.  
    5. Insert fuel injector into fuel tube with clip attached.
    6.  
    7. Insert it while matching it to the axial center.
    8.  
    9. Insert fuel injector so that protrusion of fuel tube matches cutout of clip.
    10.  
    11. Check that fuel tube flange is securely fixed in flange fixing groove on clip.
    12.  
    13. Check that installation is complete by checking that fuel injector does not rotate or come off.
    14.  
    15. Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.
    16.  

  6.  
  7. Install fuel tube and fuel injector assembly to intake manifold.
    CAUTION
    Be careful not to let tip of injector nozzle come in contact with other parts.

  8.  
  9. Tighten bolts in two steps in numerical order as shown.

    Click image to see an enlarged view

    Fig. Tighten bolts in two steps in numerical order

    1. Step 1: 7 ft. lbs. (10 Nm)
    2.  
    3. Step 2: 16 ft. lbs. (22 Nm)
    4.  

  10.  
  11. Connect fuel injector harness.
  12.  
  13. Install intake manifold collector.
  14.  
  15. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:
    1. Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them.
    2.  
    3. Thinly apply new engine oil around fuel tube from tip end to spool end.
    4.  
    5. Align center to insert quick connector straightly into fuel tube.
    6.  
    7. Insert quick connector to fuel tube until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector.
      CAUTION



      Hold (A) position as shown in the figure when inserting fuel tube into quick connector.
       
      Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
       
      Insert until you hear a -click- sound and actually feel the engagement.
       
      To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
       

    8.  
    9. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does not come out from fuel tube.
    10.  
    11. Install quick connector cap to quick connector.
    12.  
    13. Install quick connector cap with arrow on surface facing in direction of quick connector (fuel feed hose side).
      CAUTION
      If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again.

    14.  
    15. Secure fuel feed hose to clamp of quick connector cap.
    16.  

  16.  
  17. Installation is in the reverse order of removal.
  18.  
  19. Make sure there is no fuel leakage at connections as follows:
    1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
    2.  
    3. Start the engine and rev it up and check for fuel leaks at connections.
      CAUTION
      Do not touch engine immediately after stopping as engine is extremely hot.


      NOTE
      Use mirrors for checking on connections out of the direct line of sight.

    4.  

  20.  
  21. Perform procedures for -Throttle Valve Closed Position Learning- after finishing repairs.
  22.  
  23. If electric throttle control actuator is replaced, perform procedures for -Idle Air Volume Learning- after finishing repairs.
  24.  

 
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