Fuel Rail: Service and Repair

Fuel Rail

Removing








The fuel system is under constant pressure even with engine off. Before servicing the fuel rail, fuel system pressure must be released.

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

- Disconnect the negative battery cable.

- Remove the air inlet hose and upper intake manifold (2). Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.







- Remove the insulator (2) from the LH cylinder head cover.







- Disconnect the fuel injector electrical connectors.

- Disconnect the fuel supply hose (1) from the fuel rail. Refer to => [ Quick Connect Fitting Disconnecting and Connecting ] Service and Repair.








The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connector tube. Due to the design of this tube, it does not use any clamps. Never attempt to install a clamping device of any kind on the tube. When removing the fuel rail assembly for any reason, be careful not to bend or kink the tube.

- Remove the four bolts (1) from the fuel rail (2).


When removing the fuel rail from the lower intake manifold, one or more fuel injectors may remain in the intake manifold resulting in residual fuel spilling onto the engine from the fuel rail.

- Lift the fuel rail and the fuel injectors from the lower intake manifold.







- Remove any remaining fuel injectors (1) from the lower intake manifold.







- If required, remove the fuel injectors from the fuel rail. Refer to => [ Fuel Injector ] Service and Repair.

- Remove and discard all fuel injector O-ring seals (1).

Installing







- If removed, install the six fuel injectors to the fuel rail with new O-ring seals. Refer to => [ Fuel Injector ] Service and Repair.







- Clean out the fuel injector bores in the lower intake manifold.

- Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.

- Install the fuel rail (1) to the lower intake manifold with four bolts tightened in the sequence shown to 7 Nm (62 in. lbs.).







- Connect the fuel injector electrical connectors (2).

- Connect the fuel supply hose to the fuel rail (1). Refer to => [ Quick Connect Fitting Disconnecting and Connecting ] Service and Repair.







- Install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.







- Install the upper intake manifold (1), support brackets and air inlet hose. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

- Connect the negative battery cable.

- Start the engine and check for leaks.