Fuel Rail: Service and Repair

Note: In addition to the servicing of the fuel rail, this procedure should be referenced when removing or installing the fuel pressure regulator or fuel injectors.

Fig. 1:

Remove
- Reposition top edge of trunk front liner.
- Disconnect multi-plug from evaporative loss flange inset (Fig. 1).
- Switch ignition on.
- Crank engine to depressurize fuel system.
- Switch ignition off.
- Disconnect battery.
- Remove engine cover.
- Remove engine cover 1/4 turn fastener receptacles (1 Fig. 1) from fuel rail (2 Fig. 1).
- Undo fuel feed hose to fuel rail union nut (3 Fig. 1).
- Reposition fuel feed hose (4 Fig. 1) from fuel rail.
- Undo fuel return hose to fuel pressure regulator union nut (5 Fig. 1).
- Reposition fuel return hose (6 Fig. 1) from fuel pressure regulator (7 Fig. 1).

Fig. 2:

- Disconnect vacuum hose (1 Fig. 2) from cruise control actuator (2 Fig. 2).
- Disconnect vacuum hose (3 Fig. 2) from fuel pressure regulator.
- Disconnect throttle control rods from throttle pulley assembly ball pins (4 Fig. 2).
- Reposition throttle control rods to inner wings.
- Disconnect cruise control rod from throttle pulley assembly ball pin (5 Fig. 2).
- Undo and remove bolts securing fuel rail.
- Reposition cruise control rod below throttle pulley assembly.
- Remove cruise control actuator/bracket assembly and fixings (6 Fig. 2).
- Disconnect injector harness plugs (7 Fig. 2).
- Disconnect throttle potentiometer multi-plug (8 Fig. 2)
- Remove throttle pulley bracket assembly and fixings (9 Fig. 2)
- Remove injector harness plastic clips (10 Fig. 2) from fuel rail.
- Remove fuel rail/injector assembly (11 Fig. 2).

Fig. 3:

- Remove injector to fuel rail retaining clips (1 Fig.3).
- Remove injector (2 Fig. 3).
- Remove fuel regulator retaining plate and fixings (3 Fig. 3).
- Remove fuel regulator (4 Fig. 3).
- Remove and discard regulator 'O' ring seals.

Refit in the reverse order of the removal procedure.