For 1990-2009 cars

### Removal Procedures

Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Remove the engine cover. Refer to Engine Cover Replacement.
2. Remove the charge air system pipes. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.

Note: To avoid fuel spillage or damage to the injector pipe connector, hold the injector pipe connector using tools and unscrew the pipe nut. And then, put a cap on the injector connector to avoid contamination from dust as soon as the fuel pipes are removed.

3. Hold the injector pipe connector with a wrench (1) and unscrew the fuel pipe-to-injector nut (M14).
4. Hold the injection pump pipe connector with a wrench (1) and unscrew the fuel pipe-to-common rail nut (M14).
5. Unscrew the fuel pipe-to-common rail nut (M17) and the fuel pipe-to-injector nuts (M17).
6. Remove the fuel pipe-to-common rail retaining bolt from the thermostat housing.

Note: Put a cap on the common rail pipe threads to avoid contamination from dust as soon as the pipes are removed.

7. Remove the fuel pipe-to-common rail and the fuel pipe-to-injector pipes.

### Installation Procedure

Note: Do not reuse the fuel pipes. If reused, the contaminated pipes may damage the injectors or cause leak from the pipes.

1. Clean the common rail pipe threads, if contaminated.
2. Loosen the injector bracket bolts.
3. Install the fuel pipes and tighten the nuts by hand between the injectors and the common rail.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the injector bracket bolt and tighten to 28 N·m (20.7 lb ft).
5. Hold the injector pipe connector with a wrench (1) and tighten the fuel pipe-to-injector nut (M14) to 27 N·m (19.9 lb ft).
6. Tighten the fuel pipe-to-injector nut (M17) to 20 N·m (14.8 lb ft).
7. Install the fuel pipe and tighten the nuts by hand between the common rail and the injection pump.
8. Hold the injection pump pipe connector with a wrench (1) and tighten the fuel pipe-to-common rail nut (M14) to 20 N·m (14.8 lb ft).
9. Tighten the fuel pipe-to-common rail nut (M17) to 20 N·m (14.8 lb ft).
10. Install the charge air system pipes. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
11. Install the engine cover. Refer to Engine Cover Replacement.