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How to: Removal of the Plenum on the SR20 motor
(1999 Infiniti G20 SR20DE as example)
Writeup prepared by Jean-Paul LaCount
Why?
-To replace injectors/fuel rail/fuel pressure regulator
This writeup is directed for the replacment of fuel injectors, although any
of the above projects can be done using this tutorial
Total replacemnt time: 2 hours if you are careful and experienced, 3-4hrs if this is your first time.
Tools needed:
-Socket Ratchet
-3" long socket extension
-Universal joint
-12mm socket
-10mm socket
-8mm socket
-Pliers
-Needle nose vice grips
-14mm open wrench
-Large Flathead & Phillips screwdriver
Parts needed:
-Injector O-rings
4 Top (16618-10V05)
4 Bottom (16618-53J00)
-Intake Gasket (goes between plenum & intake manifold)
-Grease
Before you begin, start your car and remove the fuel pump fuse while it is
running to de-pressurise the fuel
system. Once the car dies, crank it a few times to be sure (be sure to replace
the fuse after you do this, or
else the car will not start). I would recommend disconnecting the battery since
you will be working
around fuel/fuel fumes which can be dangerous.
Begin by removing plugs and vaccum hoses as indicated in picture above. The
easiest way to remove the
electrical plugs is by leveraging a flathead screw driver between the two connections
while you press the
release lever on the plug.
Begin removing nuts and bolts to the plenum. I have found that by loosening
the throttle & choke cables allows me
to move the plenum out of the way during injector installation. You will also
need to remove the Intake tube from the
throttlebody. There are three wire loom bolts (you will see the other two just
below the one pictured above) all of
which are 10mm. You will need to remove the two emissions vaccum bolts to move
the solonoid out of the way
for bolt #7. This is where the universal joint comes in handy (bolts 1-4 &
7-9).
On the drivers side are a few wire loom bolts and a single plenum bolt (#10). Be careful not to drop these bolts!
There are several vaccum & water lines on the drivers side. It makes it
easier to remove the
intake piping to the throttle body to see these.
Once all of the bolts, vaccum lines, electrical, and water lines have been
removed, you should be able
to lift the drivers side of the plenum. You will find a third water line under
the plenum going into the intake manifold.
Dont forget to replace this one when reassembling! Once removed, you should
be able to lay the plenum in a vertical
position over the passenger side of the vehicle (still attached on that side
by several vaccum, water and electrical lines).
However, it will be sufficently out of the way for injector and fuel rail replacements/adjustments.
If you wish to leave the rail attached when replacing the injectors, use the
needle nose vice grips to loosen the screws
on the injector caps/fuel pressure regulator, you will strip the screws otherwise.
Once they are off, use a large flathead
screwdriver to wedge between the rail and injector clip. Twist and lever carefully
here. The injectors are probably still
held on by suction and the wedged O-rings. Twist slowly and hold and you will
hear the pressure releasing before the
injector is easily slipped out.
Once removed, replace the O-rings on new injectors (it is recommended you replace
the O-rings
every time you remove the injectors from the fuel rail). Be sure to
lube the O-rings very well
with grease before installation. When installing, position the injector and
press the injector into
the fuel rail by hand until you hear/feel it seat. This is very importaint,
and I have gone through several
O-rings because I did not lube the O-rings sufficently and I forced them in
using the caps. Once in, replace
the caps, and reverse process. Be sure you replace the plenum gasket especially if you are boosting!
This will ensure you have a proper vacuum seal (and no boost leaks).
Be sure you have replaced all vaccum/water/electrial lines, or you may have
trouble! I would suggest
replacing all bolts before attaching lines when possible to leave room for adjustment.
Count your lines
before and after (or use the photos as a cheat sheet) in case you removed more
that were in the tutorial.
There are a total of 3 water lines, 6 electrical plugs, and 8 vaccum lines
removed in this tutorial
Good luck!
