Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE
1. Relieve the fuel system pressure.
2. Remove the engine fuel supply and return pipes.
3. Remove the air cleaner outlet resonator.




4. Disconnect the vent pipe from the fuel pressure regulator.




5. Remove the fuel pressure regulator bolt (1).




6. Remove the fuel pressure regulator.




7. Disconnect the fuel injector harness connectors.




8. Remove the fuel rail attaching studs (1).
9. Remove the fuel rail using the following procedure:
9.1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
9.2. Rotate the fuel rail in order to position the injectors downward.
9.3. Remove the fuel rail.

IMPORTANT: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.

10. Remove the fuel injectors from the fuel rail.

INSTALLATION PROCEDURE




1. If the fuel injector insulator cups (1) are removed from the cylinder head while removing the fuel rail, new insulator cups must be installed.
2. Install the fuel injectors to the fuel rail.




3. Install the fuel rail using the following procedure:
3.1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
3.2. Align the injectors by rotating the fuel rail forward.
3.3. Carefully push the fuel injectors into the cylinder head ports.

IMPORTANT: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

4. Install the fuel rail attaching studs (1).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the fuel rail studs to 10 N.m (89 lb in).




5. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
6. Install the fuel supply and return pipes.




7. Install the fuel pressure regulator.




8. Install the fuel pressure regulator bolt (1).

Tighten
Tighten the fuel pressure regulator bolt to 10 N.m (89 lb in).




9. Connect the vent pipe to the fuel pressure regulator.
10. Install the air cleaner outlet resonator.
11. Connect the negative battery cable.
12. Inspect for fuel leaks using the following procedure:
12.1. Turn ON the ignition, with the engine OFF for 2 seconds.
12.2. Turn OFF the ignition for 10 seconds.
12.3. Turn ON the ignition.
12.4. Inspect for fuel leaks.