Fuel Injection Fuel Rail Assembly Replacement

Fuel Injection Fuel Rail Assembly Replacement

Special Tools

EN-49248 - Fuel Rail Assembly Remover

EN-47909 - Injector Bore and Sleeve Cleaning Kit

For equivalent regional tools, refer to Special Tools Special Tools.




1. Remove the fuel injection fuel rail noise shield (1). Refer to Fuel Injection Fuel Rail Noise Shield Replacement Fuel Injection Fuel Rail Noise Shield Replacement.

2. Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement Fuel Feed Intermediate Pipe Replacement.

3. Remove the fuel injection fuel rail pressure sensor. Refer to Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement.

4. Disconnect the electrical harness from the fuel rail harness connection.

5. Remove the fuel rail assembly retaining bolts and upper rubber grommets, if necessary.





Note: Use care to avoid contact with the fuel rail harness during special tool installation and fuel rail removal.

6. Install EN-49248 - studs (1) into the 2 outermost fuel rail assembly retaining bolt locations. Tighten the studs to 22 Nm (16 lb ft).

7. Install EN-49248 - remover (2) onto each stud, and engage the hooks to the fuel rail. Install the nuts (3) retaining the remover onto the studs and tighten until snug.





Note: EN-49248 will assist in the proper removal of the fuel rail assembly. Ensure that the following conditions are met:

* Turn the handles simultaneously in order to pull the fuel rail straight out along the fuel injector axis.

* DO NOT twist when pulling out on the fuel rail and injector assembly.

8. Using EN-49248 - remover, remove the fuel rail assembly.

Installation Procedure




1. Clean the fuel injector bore in the cylinder head using the EN-47909 - kit.

2. Replace the fuel rail insulators, if necessary. Refer to Fuel Rail and Injectors Cleaning and Inspection Fuel Rail and Injectors Cleaning and Inspection. Replace the fuel rail bolts, if necessary.

3. Install the fuel rail (1) with injectors into the cylinder head evenly.

Note: Mount the bolts evenly to avoid cocking of the fuel injectors during installation.

4. Hand start the 2 outer fuel rail bolts (2) to seat the injectors into the injector bores.

5. Hand start the remaining fuel rail bolts.





Caution: Refer to Fastener Caution Fastener Caution.

6. Tighten the fuel rail bolts in sequence to 25 Nm (18 lb ft).

7. Connect the electrical harness to the fuel rail harness connections.

8. Install the fuel injection fuel rail pressure sensor. Refer to Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement.

9. Install the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement Fuel Feed Intermediate Pipe Replacement.




10. Install the fuel injection fuel rail noise shield (1). Refer to Fuel Injection Fuel Rail Noise Shield Replacement Fuel Injection Fuel Rail Noise Shield Replacement.