Fuel Rail: Service and Repair

Fuel Rail

Removal

WARNING: Wait for a minimum of 1 minute after the engine has stopped before carrying out any repair to the fuel injection system.

1. Remove the cover and disconnect the battery ground cable.
2. Remove the engine cover.

WARNING:
^ Avoid flames, sparks or lighted substance.
^ Be prepared to collect escaping fuel.

3. Release the fuel pressure.





5. CAUTION:
^ Extreme cleanliness must be exercised when handling these components.
^ Make sure that all openings are sealed.





6. NOTE: Do not remove the fuel injectors, if the rail is being removed for access.





7. CAUTION: A new O-ring seal is to be installed.





CAUTION: Cap the fuel injector nozzle to prevent damage before storing vertically.

NOTE:
^ Do not disassemble further if the component is removed for access only.
^ If the fuel injectors are not being removed from the fuel rail only the lower O-ring seals will need to be renewed.

8. Remove and discard the fuel injector O-ring seals.













Installation

CAUTION: A new O-ring seal is to be installed.

1. Install the fuel rail Schraeder valve.
Torque:
6 Nm

CAUTION: A new O-ring seal is to be installed.

2. Install the fuel rail pressure sensor.

Torque: 6 Nm

NOTE: Install new O-ring seals.

3. Lubricate and install the new O-rings.
4. If removed, install the injectors.

CAUTION: A new O-ring seal is to be installed.

5. Install the fuel line to fuel rail seal assembly.

6. Install the fuel injector clamp plate.

Torque: 6 Nm

7. Install the fuel rail.

Torque: 10 Nm

8. Connect and secure the electrical connectors.
9. Install the engine cover.
10. Connect the battery ground cable and install the cover.