Fuel Rail: Service and Repair

Fuel Rail

Removing







The fuel system is under a constant pressure (even with the engine off). Before servicing any part of the fuel system, the fuel system pressure must be released.

- Release the fuel system pressure. Refer to => [ Fuel System Pressure Release Procedure ] Service and Repair.

- Disconnect the negative battery cable.

- Loosen the air cleaner outlet duct clamp at the throttle body.

- Remove the air cleaner outlet duct from the throttle body.

- Using a fuel line release tool, disconnect the fuel line quick connect fitting (1) from the fuel rail (2).

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.






• Mark the electrical harness connectors for the fuel injector with the correct corresponding cylinder numbers.

- Disconnect the electrical harness connectors from the fuel injectors.

- Remove the fuel rail bolts - arrows -.






- Gently lift fuel rail straight up and off of the lower intake manifold.






• Mark or tag each fuel injector with the correct corresponding cylinder number.

- Remove the fuel injector retaining clip from each fuel injector, if required.






- Remove the fuel injectors from the fuel rail, if required.

Installing






• Inspect each fuel injector O-ring seal - arrow - on the fuel injectors, replace any O-ring seal if damaged is noted.

- Lubricate the fuel injector O-ring seals with clean engine oil.






• Install the fuel injectors to their original locations noted during removal.

- Install the fuel injectors to the fuel rail. Ensure that each fuel injector is seated properly in the fuel rail, if required.

- Install the fuel injector retaining clips, if required.






- Lubricate the fuel injector nozzle O-ring seals with clean engine oil.

- Place the fuel rail into position on the lower intake manifold.






- Gently press down on the fuel rail over the injectors, inserting the fuel injectors into the openings in the lower intake manifold.

- Ensure that the injectors are seated and install the fuel rail bolts - arrows -. Tighten the bolts to 12 Nm (106 in lbs).

- Correctly position the engine harness and connect the electrical connectors to the fuel injectors.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.







Make sure the fuel line quick connect fitting is connected properly. Failure to connect the fuel line correctly may result in a fuel leak at the rail assembly. Fuel leaked onto a hot engine may ignite resulting in damage to the vehicle.

- Connect the fuel line quick connect fitting (1) to the fuel rail (2).

- Install the air cleaner outlet duct to the throttle body.

- Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 Nm (35 in lbs).

- Connect the negative battery cable.

- Use the scan tool auto shutdown fuel system test to pressurize the fuel system. Check for leaks.