fuel rail insulator.
CAUTION: When removing and handling, be careful not to tear the fuel rail insulator.

Insulator

Protector

Figure 36
d. While pulling back the high pressure fuel rail protector, locate and unfasten the two (2) harness clips.

Clips

Figure 37

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e. Partially pull out the high pressure fuel rail protector, and then unfasten the last harness clip.

Clip

Protector

Figure 38
39. Remove the high pressure fuel tube:
a. Carefully remove the high pressure fuel pump insulator.
CAUTION: When removing and handling, be careful not to tear the high pressure fuel pump insulator.

Insulator

Figure 39

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b. Remove the engine cover bracket bolt, and then move the engine cover bracket with vacuum
tube out of the way.
 The vacuum tube does not need to be unbolted from the engine cover bracket.

Bracket

Bolt

Tube

Figure 40
c.
d.
e.
f.

Place a shop cloth under the lower flare nut (to absorb any fuel leakage).
Loosen the lower flare nut.
Loosen the upper flare nut.
Remove the bracket bolt.
NOTE: The high pressure fuel tube is one-time use and will be replaced with a new one (see
Parts Information). Do not reuse the old high pressure fuel tube.
Upper
flare nut

Cloth

Lower
flare
nut

Bolt

Fuel tube

Figure 41
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40. Disconnect the four (4) direct fuel injector connectors (see yellow arrows in Figure 42).

Fuel rail

Figure 42
41. Place shop cloths under the high pressure fuel rail (to absorb any fuel leakage).
42. Loosen the nuts and bolts in the sequence shown in Figure 43, and then remove them.
43. Remove the high pressure fuel rail.
NOTE: Some direct fuel injectors may come out with the high pressure fuel rail. This is okay.
CAUTION: Do not remove the high pressure fuel rail fuel pressure sensor. If removed, it must be
replaced. If dropped, it must be replaced.

Fuel rail
2

4

5

3

1

Pressure sensor:
Do not drop or remove!

Figure 43
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44. Remove the direct fuel injectors:


See yellow arrows in Figure 44.

a. Spray a suitable lubricant around the injector bore.
b. Twist/rotate the direct fuel injectors to “work in” the lubricant.
c. Pull straight out to remove the direct fuel injectors.

Injector
bore

Figure 44

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Installation: Direct Fuel Injector
Refer to the following during direct fuel injector installation.
CAUTION:


Make sure to work in a clean area when handling the direct fuel injectors.



Handle the O-ring and seal ring on the direct fuel injectors with bare hands. Do not wear gloves.



Lubricate the O-ring with new engine oil before installing the direct fuel injectors.



Do NOT apply engine oil to the seal rings.



Do not clean the O-rings or seal rings with solvent.



Do not allow engine oil into the fuel passage of the direct fuel injectors.



Make sure there is no debris or foreign material on the O-rings or seal rings and their related mating
surfaces.



Be careful not to scratch, twist, or stretch the O-rings or seal rings.



Insert the direct fuel injectors straight into the high pressure fuel rail.



Install the direct fuel injector and high pressure fuel rail assembly straight into the bores in the cylinder
head.



Do not remove the high pressure fuel rail fuel pressure sensor. If removed, it must be replaced. If dropped,
it must be replaced.

Backup ring

Direct fuel injector
Seal ring

O-ring

Injector
holder

Tab

Figure 45

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1. Install the direct fuel injectors into the high pressure fuel rail:
a. Lubricate the O-ring with new engine oil.
b. Line up the tabs and cutouts, and then install the direct fuel injectors into the high pressure fuel rail,
straight in and fully seated.

Fuel rail

Cutout

Tab

Figure 46

Pressure sensor:
Do not drop or remove!

Fuel rail and
injectors

Figure 47

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2. Carefully install the direct fuel injector and high pressure fuel rail assembly:
a. Align all direct fuel injectors with their bores while fitting the high pressure fuel rail onto the studs.

Figure 48
b. With the direct fuel injectors aligned straight with their bores, push on the high pressure fuel rail until
the direct fuel injectors are fully seated.

Figure 49

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

If properly installed, the high pressure fuel rail should sit near flush to the cylinder head.

Cylinder
head

Close fit

Close fit

Fuel rail

Figure 50
c. Install, and then torque the nuts and bolts in two steps and in the sequence shown in Figure 51.
 Nuts and bolts torque:
First step: 10 N•m (1.0 kg-m, 7 ft lbs)
Second step: 25 N•m (2.6 kg-m, 18 ft lbs)
Fuel rail

4

2

1

3

5

Figure 51
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3. Connect the harness connectors to the direct fuel injectors.

Fuel rail

Figure 52
4. Install a new high pressure fuel tube (see Parts Information):
a. Thread in place by hand both flare nuts and the bolt.
b. Temporarily tighten the flare nuts until the high pressure fuel tube has no in-and-out movement at either
end.
c. Tighten the flare nuts until no threads are showing on the high pressure fuel pump or high pressure fuel rail.
d. Torque the bracket bolt.
 Bolt torque: 25 N•m (2.6 kg-m, 18 ft lbs)
Upper
flare nut
Lower
flare
nut

Bolt

Fuel tube

Figure 53
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e. Using a “crow’s foot”, torque the flare nuts in two steps, upper flare nut first.
 Flare nuts torque:
First step: 14 N•m (1.4 kg-m, 10 ft lbs)
Second step: 41 N•m (4.1 kg-m, 30 ft lbs)
CAUTION: After installation, make sure the high pressure fuel tube does not contact adjacent parts.

Crow’s
foot

Figure 54
5. Position the engine cover bracket with vacuum tube, and then install and tighten the engine cover
bracket bolt.
 10 N•m (1.0 kg-m, 7 ft lbs)

Bracket

Bolt

Tube

Figure 55
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6. Install the high pressure fuel pump insulator.
CAUTION: When installing and handling, be careful not to tear the high pressure fuel pump insulator.

Insulator

Figure 56
7. Install the high pressure fuel rail protector:
a. Install the high pressure fuel rail protector insulator.
CAUTION: When installing and handling, be careful not to tear the fuel rail protector insulator.

Insulator

Figure 57
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b. Position the high pressure fuel rail protector as shown in Figure 58, and then fasten the first clip.

Clip

Protector

Insulator
Figure 58
c. Position the high pressure fuel rail protector as shown in Figure 59.
d. Install the bolts (see arrows and callout in Figure 59).
 The bolt pointed out by the white arrow is hidden in this picture.
 Bolts torque: 25 N•m (2.6 kg-m, 18 ft lbs)
e. Fasten the two (2) harness clips to the high pressure fuel rail protector (see circles in Figure 59).

Protector

Hidden
bolt

Figure 59

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8. Connect the high pressure fuel rail sensor connector.

Sensor

Connector

Figure 60

9. Replace the water inlet pipe O-ring with a new one (see Parts Information).
 Lubricate the O-ring with coolant.

Inlet pipe

O-ring

Figure 61

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10. Replace the oil level gauge guide O-ring with a new one (see Parts Information).
 Lubricate the O-ring with new engine oil.

Guide
O-ring

Figure 62

11. Put the water inlet pipe in place, and then the oil level gauge guide.

Guide

Inlet pipe

Figure 63

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12. Install the three (3) water inlet pipe bolts (see arrows in Figure 64).
 Water inlet pipe bolts torque: 12 N•m (1.2 kg-m, 9 ft lbs)
13. Install and tighten the oil level gauge guide bolt.
14. Fasten the two (2) harness clips to the water inlet pipe (see circles in Figure 64).

Guide
bolt
Inlet
pipe

Figure 64
15. Replace the old intake manifold gaskets with new ones (see Parts Information).

Gaskets
Cover
Gaskets
Cover

Figure 65
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16. Remove the covering from the cylinder head ports and air outlet tube.
17. Carefully position the intake manifold in place:
 Do not reuse the old gaskets. Replace them with new ones (see previous page, step 15).

Intake
manifold

Figure 66
18. Install, and then tighten the intake manifold bolts in the sequence shown in Figure 67:
 Intake manifold bolts torque: 25 N•m (2.6 kg-m, 18 ft lbs)

2

3

4

5

1, 6

Figure 67
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19. Install the oil level gauge.

Gauge

Figure 68
20. Snap in place the air outlet tube to the electronic throttle control actuator.
21. Install and tighten the air outlet tube bolt.
 Air outlet tube bolt torque: 21 N•m (2.1 kg-m, 15 ft lbs)
22. Connect the electronic throttle control actuator connector.

Spring
Actuator

Outlet
tube

Connector

Bolt

Radiator
fan shroud –
driver side

Figure 69

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NOTE: The CVT fluid warmer pipes may have unfastened during repairs. Make sure they are
fastened to the cooling fan assembly.

Fan
assembly

Fluid pipe

Fluid pipe

Figure 70

23. Connect the intake manifold runner control valve position sensor connector.
24. Fasten the harness clip.

Clip
Connector

Figure 71

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25. Connect the heater hose and water hose A, and then fasten their related clamps.


See white arrows in Figure 72.

26. Install and tighten the EVAP hose bracket bolt.
27. Connect the intake manifold runner control valve motor connector.

Heater
hose