Nissan Maxima Service and Repair Manual: Fuel Injector And Fuel Tube

Exploded View

Nissan Maxima. Exploded View

  1. Fuel feed hose
  2. Quick connector cap
  3. Fuel tube
  4. O-ring
  5. Fuel damper
  6. Fuel damper cap
  7. Clip
  8. O-ring (black)
  9. Fuel injector
  10. O-ring (green)
  11.  Refer to INSTALLATION

Removal and Installation

REMOVAL

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.
  • Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
  • To avoid the danger of being scalded, do not drain engine coolant when engine is hot.

CAUTION:

  • Apply new engine oil when installing the parts as specified to do so.
  • Do not remove or disassemble parts unless instructed.
  1. Release the fuel pressure. Refer to EC-592, "Inspection".
  2. Disconnect the battery negative terminal. Refer to PG-67, "Removal and Installation (Battery)".
  3. Remove intake manifold collector. Refer to EM-25, "Removal and Installation".
  4. When separating fuel feed hose and fuel tube connection, disconnect quick connector using Tool as follows:

Tool number : 16441 6N210 (J-45488)

  1. Remove quick connector cap from quick connector.
  2. Disconnect quick connector from fuel tube as follows: CAUTION: Disconnect quick connector by using Tool. Not by prying out retainer tabs.
  3. With the sleeve side of Tool facing to quick connector, install the Tool onto fuel tube.
  4. Insert Tool (A) into quick connector (2) until sleeve (B) contacts and goes no further. Hold tool on that position.

Nissan Maxima. REMOVAL

(C) : Insert and retain

CAUTION: Inserting Tool with excess force will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.

iii. Draw and pull out quick connector straight from fuel tube (1).

CAUTION:

  • Pull quick connector (E) holding position (D) as shown.
  • Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
  • Prepare container and cloth beforehand as fuel will leak out.
  • Avoid fire and sparks.
  • Keep parts away from heat source. Especially, be careful when welding is performed around them.
  • Do not expose parts to battery electrolyte or other acids.
  • Do not 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, etc. (A) or something similar.

Nissan Maxima. REMOVAL

  1. Disconnect harness connector from fuel injector.
  2. Loosen bolts in reverse order as shown, and remove fuel tube and fuel injector assembly.

Nissan Maxima. REMOVAL

: Engine front

CAUTION: Do not tilt fuel tube, or remaining fuel in pipes may flow out from pipes.

  1. Remove fuel injector from fuel tube as follows:
  2. Open and remove clip (1).

 

(3) : O-ring (green)
(4) : O-ring (black)
(A) : Installed condition
(B) : Clip groove

Remove fuel injector (2) from fuel tube (5) by pulling straight.

CAUTION:

  • Be careful, fuel may leak from the fuel tube.
  • Be careful not to damage injector nozzle during removal.
  • Do not bump or drop fuel injector.
  • Do not disassemble fuel injector.
  • Do not reuse O-rings.
  1. Remove fuel damper from fuel tube.

INSTALLATION

  1. Install fuel damper as follows:
  1. Install new O-ring (2) to fuel tube (1) as shown. When handling new O-ring, be careful of the following caution:

CAUTION:

  • Handle O-ring with bare hands. Do not wear gloves.
  • Lubricate O-ring with new engine oil.
  • -Do not 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, nick or damage it.
  • Be careful not to twist or stretch O-ring.
  • Insert new O-ring straight into fuel tube. Be sure O-ring is centered and not twisted.
  1. Install spacer (3) to fuel damper (4).
  2. Insert fuel damper straight into fuel tube.

CAUTION:

  • Insert straight, checking that the axis is lined up.
  • Do not pressure-fit with excessive force.
  • Insert fuel damper until (B) is touching (A) of fuel tube.

Nissan Maxima. INSTALLATION

Reference value : 130 N (13.3 kg, 29.2 lb)

  1. Tighten bolts evenly in turn.
  • After tightening bolts, check that there is no gap between fuel damper cap (5) and fuel tube.
  1. Install new O-rings to fuel injector paying attention to the following.

CAUTION:

  • Upper and lower O-ring are different. Be careful to install them in the correct location.

Fuel tube side : Black
Nozzle side : Green

  • Handle O-ring with bare hands. Do not wear gloves.
  • Do not reuse O-rings.
  • Lubricate O-ring with new engine oil.
  • Do not 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, nick or damage it.
  • Also be careful not to twist or stretch O-ring.
  • If O-ring was stretched while it was being attached, wait for it to return to the original shape before inserting it into the fuel tube.
  • Insert O-ring straight into fuel injector. Do not decenter or twist i
  1. Install fuel injector to fuel tube as follows:
  2.  Insert clip (3) into clip groove (F) on fuel injector (5).

Nissan Maxima. INSTALLATION

(2) : O-ring (black)
(4) : O-ring (green)

  • Insert clip so that protrusion (E) of fuel injector matches cutout (C) of clip.

CAUTION:

  • Do not reuse clip. Replace it with new one.
  • Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.
  • Do not reuse O-rings.
  1. Insert fuel injector into fuel tube (1) with clip attached.
  • Insert it while matching it to the axial center.
  • Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip.
  • Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip.
  1. Check that installation is complete by checking that fuel injector does not rotate or come off.
  • Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.
  1. 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.

  • Tighten bolts in two steps in numerical order as shown

Nissan Maxima. INSTALLATION

: Engine front
1st step : 10.1 N*m (1.0 kg-m, 7 ft-lb)
2nd step : 22.0 N*m (2.2 kg-m, 16 ft-lb)

  1. Connect fuel injector harness.
  2. Install intake manifold collector. Refer to EM-25, "Removal and Installation".
  3. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:
  4.  Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them.
  5.  Thinly apply new engine oil around fuel tube from tip end to spool end.
  6.  Align center to insert quick connector straightly into fuel tube.
  • Insert quick connector (1) to fuel tube until top spool (2) is completely inside quick connector, and 2nd level spool (3) exposes right below quick connector.

Nissan Maxima. INSTALLATION

(B) : Fitted condition
: Upright insertion

CAUTION:

  • Holding position (A) 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.
  1. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does not come out from fuel tube.
  2. Install quick connector cap (3) to quick connector.

Nissan Maxima. INSTALLATION

(1) : Fuel feed hose
(2) : Fuel tube
(B) : Upper view

  • Install quick connector cap with arrow (A) 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.

  1.  Secure fuel feed hose to clamp of quick connector cap.
  2. Installation is in the reverse order of removal.

Inspection

INSPECTION AFTER INSTALLATION

Check For Fuel Leaks

  1. Turn ignition switch "ON" with the engine stopped. With fuel pressure applied to fuel piping, check for fuel leaks at connection points. Repair as necessary. NOTE: Use mirrors for checking at points out of clear sight.
  2. Start the engine. With engine speed increased, check again for fuel leaks at connection points. Repair as necessary. CAUTION: Do not touch the engine immediately after stopped, as the engine becomes extremely hot.
    Ignition Coil

    Rocker Cover